# Optimized Manufacturing for Automotive Engine Components
> Explore engine manufacturing system design, including production targets, make-vs-buy strategies, assembly flows, and operational buffer optimizations.

Tags: manufacturing-engineering, automotive-industry, production-planning, operations-management, assembly-line, process-engineering, industrial-design
## Engine Manufacturing System Design
* Final exam presentation focusing on gross planning and process engineering for automotive 2026.

## Gross Planning & Production Targets
* Target throughpout: 915 engines per day.
* 2-shift operation totaling 16 hours/day.
* Strategy: Parallel lines feeding into final assembly.

## Make vs. Buy Strategy
* **In-House:** Oil Sump, Piston Head, and quality-critical components.
* **Outsourced:** Engine Block, Crankshaft, Camshaft, Fasteners, and Manifolds.

## Manufacturing Processes
* **Oil Sump Line:** 68 units/hour (1080/day). Involves shearing, deep drawing, trimming, laser welding, and leak testing.
* **Piston Head Line:** 172 units/hour (2745/day). Includes turning, milling, drilling, honing, and diameter finishing.

## Sequential Assembly Flow
1. Pistons assembly to cylinder heads.
2. Piston block to engine block integration.
3. Crankshaft and bearing installation.
4. Camshaft system setup.
5. Front/Back panel attachment.
6. Oil sump installation.
7. Timing belt system.
8. Final manifolds and plugs.

## Production Layout & Logistics
* **Oil Sump:** Flow-line layout with buffers.
* **Piston Head:** Island/Cell manufacturing using high-precision machining centers.
* **Logistics:** Forklift delivery of raw materials to assembly buffers.

## Operational Metrics
* Process Lead Times (seconds): Piston Head (133s), Oil Sump (147s), Final Assembly (505s).
* Workforce distribution: 13 workers for oil sump, 37 for piston heads.

## Buffer Strategy
* Optimized for 97.3% synchronization.
* Oil Sump Buffer: 165 units.
* Piston Head Buffer: 22–28 units.
* Assembly Input Buffer: 30–35 engine sets.

## Economic Overview
* **Raw Materials:** 3mm Mild Steel and Aluminum Slugs.
* **Cost Breakdown:** Materials (45%), Labor (25%), Machining (20%), and Overhead (10%).
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