1.

Layout
The random layout adapted in the system make many problems in
production. Like the material handling time wasting, storage spaces and
buffer zones, miscommunication between different workstations and
increasing the scrap rate. Thus, we introduced to use cellular Layout for the
following reasons:
The industry is classified as a medium production quantity plant as it
produces an annual number of units of around 10,000 units.
The variety of the products could be considered soft to medium
because the batches come with different designs but therere common
processing operations.
The processing of different parts is accomplished in a cell consisting of
several machines, and the classification of cells would be according to
their capacity. High, medium and low capacity with common machines
between them.
2. 5S: Sort, Set, Shine, Standardize, Sustain
Theres no doubt that using the 5Ss approach will reduce the cycle time as it
reduces the waste time. We noticed that when workers need specific tool,
they leave their machines and start looking for the needed tools, and after
that they dont return them to specific locations.
3. Flow and sequence of operations to reduce work in process:
The flow of operations should be restudied in order to reduce the cycle time
and enhance the quality of the final part. This will also decrease the number
of movements and the amount of the material handling in the plant as a
quantity and frequency.
4. Material handling automation by using carts:
We introduce using carts that follow a railway to connect between the
different workstations easily and to reduce the time and effort in the material
handling operations. This will also reduce the area occupied by the work-inprocess parts.
5. Leveling the land of the factory
We noted that the land of the plant is multileveled, which makes the
possibility for implementing a material handling system hard, and also this
increases the chance of safety accidents, like falling down.
6. Using boxes to collect sheared sheets behind the Metal-Sheet shearing
machine:
At the back side of the shear, where the final products (at this stage) are
going out of the shear, they could be cumulated in a box to store them
temporary, instead of having a worker to go down for moving the parts to the

next location in multistep. This will also decrease the safety hazards for
workers, like causing the low back pain and causing injuries during standing
up each time.
7. Scrap classification according to size:
We noticed that the scrap is randomly stored without any classification. We
introduced classifying the scrape according to their size so that we could
easily access them and use the wanted ones when needed. We could also
know for a batch if we could do it with scrap units without taking long times
for searching.
8. Scrap storing out of the production line:
A serious problem we noticed is that the plant space itself is used for storing
the final materials which is a bad behavior for many reasons, it affects the
movement in the plant, it also make a serious hazardous areas and waste in
the spaces.
9. Safety considerations: using safety guards, gloves, guards for pedals for
initiating processes:
Its agreed that following safety considerations lead to increasing productivity.
We noticed that the working environment is not safe for the workers. For
example, the workers do not wear gloves even that they work with sharp
material (thin sheet metals). Moreover, workers on the shearing machine