g RotoBreak Cassette Assembly Station Optimization By Randy Greenberg SMA Due Date: 12/14/99

g RotoBreak Objectives: Produce 1000 cassette assemblies per week for each of 3 worldwide locations Use common processes and procedures for interchangeability 40 hour work week 75% location utilization

g RotoBreak Measure of success: 1000 units per week Maintain 40 hour shift 75% location utilization

g RotoBreak Schedule: Data collection 11/01/99 Working model with recommendations 12/7/99 Validation of model 2/15/00 Revision to model 3/15/00

g RotoBreak Product description:  Cassette module used in circuit breaker to make and break the circuit  Key components are: 1.Cassette housing 2.Rotor 3.Contact arm 4.contacts 5.Straps 6.Springs 7.Pins 8.Arc chute 9.Ablative material 10.Links

g RotoBreak Simulation layout Work area breakdown Welding   Line and load strap T(59,63,72)   Contact arm welder T(95,110,130) Staking  Second link to contact arm T(40,50,61) Molding  Cassette Deflasher T(310,345,400) Arc chute assembly  Arc chute T(57,64,75) Assembly  Rotor assy T(65,71,82)  Strap to cassette T(67,71,90)  Arc chute insulation and rotor to cassette T(95,105,110)

g RotoBreak Initial Layout

g RotoBreak Results-first run 383 units output Run for 37.5 hours deflash bottleneck Double number of deflash stations

g RotoBreak Initial run output

g RotoBreak Results-First modification 766 units output Deflash still bottleneck Add third station

g RotoBreak First modification run

g RotoBreak Results-Second modification Output 1000 units Strap to cassette utilization only 65% Combine ablative material with strap to cassette location Transfer 20 seconds to this station

g RotoBreak Second Modification output

g RotoBreak Final results Utilization greater than 75% combine rotor and second link to contact arm staker

g RotoBreak Final Results

g RotoBreak Conclusion Capable of meeting goal of 1000 units per week Need to add two additional deflash stations Combine rotor and second link to contact arm staker operations