INTRODUCTION 1 METHODOLOGY 36 Lead Time Improvement By Re - Layout At Aerospace Company (Ctrm Aero Composite Sdn Bhd).

v TABLE OF CONTENTS Abstract…………………………………………………………..………………...….i Dedication……………...…………………………………………………………….iii Acknowledgement……………..…………………………………………………….iv Table of Contents ……………………………………………………………..……...v List of Figures ………………………...………………………………………….....xii List of Tables …………………….………………………………………………...xvi List of Abbreviations, Symbol and Specialized Nomenclature…………………...xviii List of Appendices …………………………………………………….…………...xix

1. INTRODUCTION 1

1.1. Introduction 1 1.2. Project Background 2 1.3. Problem Statement 3 1.4. Aims and Objective 3 1.5. Scope of Project 4 1.6. Expected Result 4 1.7. Methodology and Flow Chart 5 1.8. Summary 5 2. LITERATURE REVIEW 7 2.1 Introduction of plant layout 7 2.2 The Plant Layout Problem 9 2.2.1 Minor changes in present layouts 10 2.2.2 Existing layout rearrangement 10 2.2.3 Relocating into existing facilities 10 2.2.4 Building a new plant 11 2.3 Objective of layout planning 11 2.4 Traditional Types of Facility Layout 11 2.5 Non-Traditional Types of Facility Layouts 12 vi 2.5.1 Agile Manufacturing Layouts 13 2.5.2 Flexible Plant Layouts 14 2.5.3 Fractal Layout 15 2.5.4 Holonic layout 16 2.5.5 Hybrid Cellular Layouts 16 2.5.6 Modular Layouts 17 2.5.7 Multi-Channel Manufacturing 17 2.5.8 Organization of Factories as Responsibility Networks 18 2.6 Trends in Facility Layouts observed in Industry 19 2.6.1 Reconfigurable Manufacturing Systems RMS 19 2.6.2 Flow Manufacturing – Linked Cells 20 2.7 Systematic Layout Planning With Production Flow Analysis 21 2.8 Tools for design of facility layouts 25 2.9 Company Overview CTRM Aero Composite Sdn Bhd 30 2.9.1 Introduction 30 2.9.2 Process Flow: A320 Phase 1- Leading Edge LE, Tailing Edge TE, Aileron, Over Wing, Under Wing, A320A321 Affixed Fairing, Movable Fairing 32 2.9.3 Process Flow: A320 ASSY Top Skin False Work 33 2.9.4 Process Flow: A320 Phase 2 Spoiler 34 2.10 Summary 35

3. METHODOLOGY 36

3.1 Introduction 36 3.2 Project Overview 37 3.3 Problem Identification 37 3.4 Data collection 39 3.5 Data Analysis 39 3.5.1 Process Analysis Technique 39 3.5.1.1 Conduct a Preliminary Study 40 3.5.1.2 Draw Up a Process Flow Chart 40 3.5.1.3 Record Measurements for All Required Items 41 vii 3.5.1.4 Draft an Improvement Plan 41 3.5.1.5 Data Comparison between Current Condition and Improvement Plan Using Pareto Chart. 41 3.5.2 Workplace Analysis 43 3.5.2.1 Illuminance Noise Measurement 43 3.5.2.1.1 Selecting the Workplace 45 3.5.2.1.2 Set Up the Equipment 45 3.5.2.1.3 Collecting Data 45 3.5.2.1.4 Analysis Data 45 3.5.2.1.5 Suggestion and Improvement Plan 45 3.5.2.2 Muscle Fatigue Assessment 46 3.5.2.2.1 Preparing the Questionnaire 46 3.5.2.2.2 Select the workplace 46 3.5.2.2.3 Analysis the questionnaire 47 3.5.2.2.4 Suggestion and Improvement Plan 47 3.6 Proposed the New Layout 49 3.7 Summary 49

4. RESULT AND ANALYSIS 50