Detailed Design Review Nathan Arrowsmith, Samantha Reinhart, Rachel Short, Yelena Tuzikova SR

Supplier Kitting Idea “Top 16 BOMs” SR

Current Kitting Observations: Purpose / Benefits: -Cell associate kits jobs a few days ahead of time which allows her to know if she has enough parts for the job -Helps her know which jobs to work on -Reduces assembly time: all parts are directly at POU (time study still needs to be completed) Observations: -Takes 2-5 minutes to kit each job (this work could be redistributed in future) -Not in standard work -Cell associate currently works on orders in order dependent on: if she has parts and if the machine is already set up SR / RS

General Material Presentation Rules and How They Can Be Applied to 922A “What good looks like” Parts are oriented so that a quick visual estimate of the quantity can be made. Flanges, dials and other cylindrical parts are kept upright. Parts with large kanban size and small unit volume are subdivided. Parts are easy to replenish and retrieve during assembly. Rods are stored in tubes with enough space around them to not get tangled. Tools are not blocking view of parts. They can have dedicated storage inside the bin or go to an existing flexible tool storage. YT (These are a combination of the rules from last reviews and the comments we got, in addition to a few new rules) Numbered items are general, repeatable, material rules and the lettered items are the rules that our specific cell would follow using the general rules as a guideline b. For example, if there is a large kanban size and small unit volume, the parts should be split into smaller quantities that are easy to visually estimate the count ( like 100’s or 500’s). If this was done for screws, you could set dividers in the bin that when the screws take up the full volume inside the divider it is that certain amount. This way the parts would never need to actually be counted an extra time during replenishment. Rods applies to aisle 1 tools in bins applies to aisle 2

Material Presentation Rules Continued Parts are in containers of appropriate size and color. Color: Electronics in black bins. VMI items in another color (green?). Remaining fabricated and purchased items in yellow or white bins Size: No oversize bins blocking view of other bins. No bins overflowing with parts. Width of each machine station and assembly area is minimized. Plan for enough room to store one days worth of corrugated. Vertical storage is utilized where available. Color: VMI items in another color bin (purple?) Size: Oversized bins decrease visibility for smaller, more recessed bins.For example, out of the ten minutes spent practice kitting a BOM in the swedish parts station, about 3 was spent looking for two small blue containers that were next to extra long containers that were less than a tenth full. Ex. hardware in swedish assembly location Width of each station should only be enough for the machine and some tabletop space to place assemblies that are WIP. Part storage should be as vertical as possible, taking into account reachability for the cell associate

Material Presentation Rules Continued All dedicated storage is clearly defined Dedicated storage for overstock and repack floor space in aisle 2 All flexible storage is clearly defined Overstock fabricated parts Visual information is clearly visible. Part number for all locations Minimum and maximum quantities for non-kanban fabricated part locations Kanban part locations have either a kanban card or a purple laminated card indicating the item is on order 7. Max and min quantities are Kurt’s idea. For kanban items, as mentioned last review, all parts with either have a kanban card readily accessible or one of the purple laminated cards indicating that the item is on order

Future State Ideas Aisle 1: Arrange by machine is most effective - have Kanban quantity at POU Utilize unused vertical space better throughout Aisle 2: Have overstock with Kanban cards Organize “Swedish” station by part number with the exclusion of heavy and large bins which are kept at bench level or underneath. Cell associate wants bins organized by frequency with infrequently used parts higher up on the rack. This setup is highly problematic for the W.S. Two out of four rows of the “Swedish” parts rack are unused Moving of repack operation? YT These are in addition to implementing material presentation rules throughout the cell Aisle 1: There is definitely adequate room at each machine station to fit the proper quantities of all items at each station Decrease footprint of machine stations by moving parts up, taking into account machine maintenance restrictions Aisle 2: Aisle currently consists of the repack operation, the “Swedish” station, and dedicated overstock Cell associates current arrangement of the swedish parts took nate 10 minutes to kit one order as opposed to 4 minutes when organized by number and weight. The top rack is impractical to use because of the height Moving of repack operation: -Jen suggested this in January but was turned down -The idea is to move the entire repack job out of Jen’s cell and into the other repack cell in the building -This would completely clear the two underutilized floor spaces remove the need for the smaller white table

Tests/Experiments Tape test Self-reporting Alphanumeric ordering in Aisle 2 (bench 8) Normal vs Abnormal ideas NA

Tape Test Test: Taped off areas identified in Aisle 2 as under-utilized in our last review. Review on visits and ask Jen if tape has been breached. Status: Preliminary results - Repack area rarely utilized in full. Usually only half-utilized. Areas adjacent to overflow/kit racks very under-utilized. NA Our results: half of “repack area” seems underutilized, ¼ of table underutilized, area next to assembly table in aisle two underutilized Conclusions: we can use for over stock Next steps:

Tape Test Pictures & Conclusions Conclusion: We should evaluate the efficacy of merging the repack task in this cell with another function. NA - I’m referring to merging repack here with repack from the other cell that does RP but I’ve worded it in a more open ended way to suggest that other possibilities may exist. I know they evaluated moving 922’s repack to another cell that does repack in the past but decided not to.

Alphanumeric Bin Organizing Test: Compared time to locate materials on a BOM in the kitting/over stock area with the pre-existing bin locations vs. an alphanumeric arrangement. Status: Confirmed that alphanumeric arrangement takes less than half the time. Some apprehension with cell associate. Awaiting feedback after use. NA

Self Reporting Test: Have cell associate log material activities that require leaving the cell or that negatively affect production. Status: On-going- will be extending to water spider. Observations: -Spends time getting shared components from other cells (few times a week, about ten minutes each time) -Spends time getting VMI parts from outside cell (few times a week, about two minutes each time) -Leaves cell to get boxes and labels frequently NA Time/ waste associated with inventory/components What we did: give jen time sheet Our results: go get screws from VMI 2x a week (2 minutes each time); get parts from other cell (2x week, ten minutes each), go get boxes 2x a week = 2 minutes each, get labels 5x a day- 30seconds each, someone else needs machine 2x a week – 15 minutes each Conclusions: other wastes could be explored, bring shared parts into cell Next steps: extend to water spider

Normal vs. Abnormal Are the following normal or abnormal? Cell Associate regularly leaves cell to retrieve component parts. Cell Associate kits own parts. Cell Associate adjusts production schedule due to missing parts. Infrequently used parts are stored in large quantities. Space is almost always utilized completely. NA - This should be fleshed out more. I’ll talk about the purpose of these questions and we can get the meeting attendees feedback on these and emphasize that we’ll also be asking other stakeholders. Feel free to add normal/abnormal states

Project Plan SR

Preliminary MSD II (Fall) Plan: Assess and complete implementation Review audit sheet Determine which cells our rules could work in: design for exceptions Tape (space) test for other cells -Goal: justify space savings and potentially combine extra space -Extra space used for more central storage (kitting?) SR