1. BLUE BARRACUDAS SEAN EAGAN BECCA WHELCHEL MARC MCDONALD THOMAS SPURLOCK WILL STUMP NASSER ALI Stained Glass Mosaic Production

2. What are our goals? Create an efficient production system Apply principles learned in IE 200 & 220 Work as a team

3. Production Overview 3 different types of glass must be cut into different shapes to form a flying WV symbol The pieces of glass are glued onto a piece of plywood Grout the entire mosaic Refine product and adhere felt backing

4. Work Assignments TaskAssigned toTime per Mosaic Total Time Blue glass cuttingSean Eagan, Thomas Spurlock, Nasser Ali 9 minutes 54 seconds 59 minutes 24 seconds Yellow/White glass cutting Will Stump, Marc McDonald 1 minute 35 seconds 9 minutes 30 seconds GluingBecca Whelchel3 minutes 52 seconds 23 minutes 11 seconds Stencil CuttingMarc McDonald33 seconds3 minutes 18 seconds GroutingSean Eagan10 minutes 23 seconds 62 minutes 18 seconds *Time was calculated using the MOST method

5. Initial Problem Improvement 1. The grinding process took far too much time 2. Nipped glass would scatter as it was cut 3. Gluing the white glass took far too much time moving one at a time 4. Determining which face of the glass should face up took too much time, and was often inaccurate 5. Cutting glass is the longest and most difficult process 1. Cuts were made more carefully, and cutters improved their cutting skills 2. A box was used so the scattered glass could be quickly recovered 3. Glue was applied to a wide area and many white squares were glued at the same time 4. The dull side was marked so it could be easily identified 5. More people would be set on this task

6. Initial Problem Improvement 1. Whole mosaics would take longer to make if each glass cutter cut each piece 2. Often too much glass was nipped 3. Loose cut glass pieces were often confused, or misplaced causing recutting 1. The cutters were assigned various different pieces to specialize and cut so the gluers could pull the pieces and complete the mosaics. 2. Gluers would pull the various pieces from the nipper as they needed them, acting as a kanban, freeing a worker to do other jobs that required more attention 3. A labeled board was set up to allow quick identification of the various pieces

7. Workspace Layout and Spaghetti Diagram

8. Quality Control Grind poorly cut blue pieces Use template to nip yellow glass and tesserae into same-size pieces Use no more or no less glue than needed Carefully monitor grouting process Remove excess grout

9. Safety Practices Goggles must always be worn to protect eyes from glass Water must always be in the grinding machine, to prevent overheating Cutter and nipper operators must be trained with the tools Glass should be nipped down, and away from faces and other persons

10. Cost Analysis – Overhead Costs Overhead Costs Cost / week Percentage Used Overhead Cost/week Overhead Cost/month Total Cost Utilities$10020$20$80$280 Overhead$25020$50$200 Total$480

11. Cost Analysis – Material Costs MaterialCostTotal Needed Total CostCost per mosaic Glue$4.00 per tube20 tubes$80.00$0.08 Foundation Boards $0.25 each1000 boards$250.00$0.25 Tesserae$0.20 per pound 1000 tesserae$50.00$0.05 Yellow Glass$10.00 per sheet 67 sheets$670.00$0.67 Blue Glass$8.00 per sheet 45 sheets$360.00$0.36 Grout$4.00 per lb.167 lbs.$667.00$0.67 Total$2077.00*$2.08* *Assuming no step has to be redone, which is improbable

12. Cost Analysis - Labor Labor TypeTaskStandard Time Time per unit Total labor Cost Labor at 12$/hr Cutting blue pieces 59 hr199 sec/unit$702.48 Labor at 8$/hr Nipping, grinding ect. 101 hr342.72 sec/unit $808.82 Total$1511.30

13. Cost Analysis *Assuming all 1000 units are sold

14. What We Learned How to create an effective and efficient production system How to work as a group and solve problems together How to IE 200 and 220 principles apply to real systems