Senior Design I Peer Review January 20 th, 2006 PO6208 – ARC Works Sports Bottle Sponsor: ARC Works of Monroe County Team Members: Team Leader George Gooch, Chris Donati, Drew Stone- Briggs, Hui Kim, Mike Hayden, Mike Levis, Jeff Coppola, Bill Lucas Mentors: Dr. DeBartolo (ME) and Dr. Marshall (IE)

Project Overview The Following is a Basic Overview for the Purpose of the Project:  Faster and more automated production  Less rejected assemblies  More convenient and ergonomic work stations  Better inventory management Background, to Date  Met with sponsor to discuss objectives  Created needs assessment based on meetings  Began conceptualizing solutions Design Team - ‘Brainstormed’ different options for each process Inventory Management Team - Began working with inventory program

Project Overview (Cont.) Basic Assembly Finished Enclosure Components Closure (Various Sizes) Adapter Straw (tube) (Various Lengths)

Project Overview (Cont.) 1 st Operation: Straw Cutting Process Machine 10 Straws at once are inserted into the top of the automated straw cutter. The machine cycles, cuts the straws and they drop through into a box.

Project Overview (Cont.) 2 nd Operation: Adapter / Closure Insert Process Machines Closures are placed in the bottom fixture and Adapters are placed in the top fixture of one of two style manual presses. The presses are cycled to create the Closure / Adapter Sub- assembly.

Project Overview (Cont.) 3 rd Operation: Final Assembly Press Process Machine Closures / Adapter Sub Assemblies are placed in the top fixture of the automated press. Straws are placed in the bottom fixture. The machine is cycled to create the final assembly.

Design Ideas for the Closure Tube Assembly Process Improve tube cutter loading Combine all assembly steps Increase productivity using automated feeders Improve ergonomics & safety Add electronic parts counter

Tube Cutter Improvement Modifying vs. replacing existing equipment Standardizing machine components Expanding the capacity of the tube holder Adding electronic parts counter Improving ergonomics

Tube Cutter Improvement Manual Tube Feeding Concept

Tube Cutter Improvement Discussion: Methods for improving throughput, especially loading of tubes into cutter  Manual vs. Automated  Increase batch size

Assembly Process Improvement Pin Style Automated Press Discussion: Pin tube support Sliding Adapter Fixture Press Discussion: Closure Interference, Fixture Alignment, Adapter Orientation

Assembly Process Improvement Two Stage CTA Press  Discussion: CTA Removal, Rotation CTA Process w/ Magazine Feeder  Discussion: Alignment

Feeding Concepts Automated Feeding  Discussion: Cost, Complexity, Durability, Clip Manufacturability Also… Closure? Feed Escapement TubeAdapter

Current Inventory Issues Sponsor’s concerns include :  Tracking sub-assemblies through the system  Running different types of reports such as sales and inventory  The ‘Writing Assistant’ function of Great Plains  Cycle counts  Using Great Plains to help with Safety Stock and reorder points  Inputting data as a transfer of materials rather than an adjustment  Subtracting on-hand components from the system when a kit is completed  Utilizing the software to set up a backorder system to fill shorted kits

Current Inventory Issues Discussion:  Metrics to weigh improvements against  How to relate this issue to IE criteria vs. just teaching them how to use the system  How much time should we put into learning the system vs. the amount we can actually help them in a way that is significant in our senior design

Goals Desired Outcomes – Stage 1 (Winter)  Develop an understanding of areas needing improvement  Finalize design concepts that meet customer goals  Learn the current inventory management system  Come to an acceptable design Develop project BOM and estimated costs Desired Outcomes – Stage 2 (Spring)  Faster production by the ARC Works team  Less backorders and established safety stock  Fewer rejects  Higher satisfaction of workers This material is based upon work supported by the National Science Foundation under Award No. BES Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation.

This material is based upon work supported by the National Science Foundation under Award No. BES Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation. Questions???