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Team Members Stefan Enjem – ISE Joe Van Hofwegen - ISE Young Lee - ISE Joe Pecht - ME Walter Freitag - ME Jason Zion - ME Luis Garcia - EE IE MEEE
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Hydraulic Fan Motors Who uses them? Why are they used? How are they built?
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Needs Assessment QPH (9) 4 to 6% Increase in Production 2 year payback Safety and Quality
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Organization Scope and Resource Distribution Work Breakdown Structure Scheduling Gantt Chart Communication Yahoo Web Group
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Deliverables Standardized Procedures Preventative Maintenance Set Production Guidelines Fix Problematic Stations End of Line Tester Efficiency Identify improved system configurations
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Organizational Structure Project Manager Stefan Enjem Procedures Jason Zion Simulation Joe VH Problem Stations Joe Pecht Controls Luis Garcia Data Analysis Young Lee EOLT Walter Freitag
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Data Collection and Analysis Data Collection Motor Counters EOLT Data Sheets Cycle Time Historical Data
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Bottleneck Identification Histogram shows major sources of backup
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Micro-stop Micro stop = Downtime of less than 5 minutes
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Industrial Standards Clean Room Certified Class 100,000 QS 9000 Quality standard TS 16949 Valeo Union Standard 423 minutes per shift Ergonomic Guidelines
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Detailed Procedures Standard Procedures Worker Rotation Failure Response Plan
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Manual Stations Current Problems Concept for Improvements Expected Improvements Station 90 Station 160
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Preventative Maintenance Creation of a Preventative Maintenance Schedule
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Station 210 Current Problems Camera for Optical Test Leak Test Connectors
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Concepts for Improvement –Mirror –PM on Rubber Connectors Expected Improvements –Reduction in Downtime Rubber Connectors Station 210
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End of Line Tester Function Current Problems Feasibility of Concepts
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Mounting Concept Linear Slide Mount
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Mating Concept Modified Assembly Cell Balancer
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Technical Analysis FEA Air Cylinder Sizing Expected Improvements
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Arena Simulation – Our Test Plan Analyze system as a whole Identify optimal system configuration and alternatives Using pallets, conveyor speed, queue sizes Justify Improvements
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Cost Analysis of Total System Estimated Cost Analysis Net Present Value
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Future of Project Engineering Models Head start Simulation Stations Detailed Design Meet the Goal
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Backup - Bill of Materials
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Backup - Regression
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Backup – Bottleneck Rank Bottleneck Ranks RankStationAvg Cycle Time 1EOL44.07 29036.93 316035.48 410022.18 5170A21.17 6140A20.85 7200B20.80 8110B20.50 9120B19.66 1021017.71 11140B17.20 1218016.85 1320516.69 14120A15.86 15150B15.07 1619015.01 17200A14.94 18110A14.88 19150A12.95 20170B11.65 21230B11.48 22230A10.78 231306.29
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Backup - WBS
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Backup –Gantt Chart
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Backup – Counter Data
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