Applying Lean Manufacturing Philosophies and Visual Factory Philosophies in the Pneumatic Valves Assembly Cell at Hamilton Sundstrand A Senior Project by: Joseph G. Nocon & Andrew G. Corlett Faculty Adviser: Company Sponsor: Dr. Eric Haffner Hamilton Sundstrand Friday, April 25, 2003

Introduction Pneumatic Valves Assembly Cell –32 Different types –3 Different assembly lines Two bench build line One flow lines –Internal Kanbans –Finished-good Kanbans

Objectives Balance assembly cell –Cycle times < Takt times Improve visual flow Reduce WIP Reduce cycle times Reduce batch sizes

Methodology Analytical Method –Balancing the line Visual Method –Improve visual flow Computer Simulation –Reduce cycle times –Improving product mix

Analytical Method Data Collection –Time Trials –Process Sheets Combine processes –Part Families –Sub-Assemblies Batch Size

Visual Method Flow Diagrams Standard Work Combination Sheets (SWCS)

Computer Simulation Collect and Analyze data Use of Taylor Ed. Create initial model –Arrival list –4Dscript –Excel

Computer Simulation cont.

Validation & Verification –Actual system vs. Simulated system Develop improved model –2 workers vs. 1 worker –Modify Arrival list –Perform ‘what if’ analysis

Results Analytical –Part #’s & Reduced cycle times Reduce WIP Single-piece flow (batch size from 4-1) –Part #’s & Reduced batch size from 4-3 Reduced cycle time

Results cont. Visual –Flow Diagrams & SWCS Computer Simulation –‘What if’ analysis results Cycle times reduced by 9-90% WIP reduction Increase throughput

Conclusions Visual –Visual indicator make it easier for a non-cell member to get easily acclimated with the flow of the line. Analytical –Reduction of batch sizes and single-piece flow assist in eliminating waste. Computer Simulation –With the use of two workers, the product mix can be more flexible and lead-times can be reduced.

ABET Topics Manufacturability Sustainability Environmental Concerns and Implications Health and Safety Concerns and Implications Social Concerns