Improving Regrind Process - iowastem.org

PartI:GeneralOverviewofBusinessAmericanProfolislocatedinCedarRapids.Theyproducecastfilm,(rollsofplastic).TheCedarRapidslocationistheonlyproductionfacilityinNorthAmerica.Thebusinesshastwomorefacilitieslocatedacrosstheglobe.OnefacilityislocatedinChinaandthecorporateheadquartersandanotherproductionfacilityareinGermany.TheCedarRapidsfacilitybeganoperationin1992.Thecastfilmproducedisutilizedinnumerousproducts.Forinstance,oneoftheirbiggestcustomersusesProfol’sproductstomanufacture3ringbinders.Profol’sbusinessanchorstheirbeliefsonthreeprimarycornerstones:Quality,Innovation,andValue.

PartII:JobSpecificsTheprobleminvolveseveryoneintheproductionfacility.Managementandqualitycontrolidentifytheproblem,thoughthemessagemayhavebeenrelayedfromproduction.Theplantengineersrespondtotheissuesanddevelopsolutionstoresolvetheconcerns.Themaintenancedepartmentinstallsorrefurbishestheequipmenttodiminishtheproblem.Finally,productionoperatorsandtechniciansfollowplansandupdatedoperationstohelpminimizethedilemma.Eachmember’scommunicationandcooperationisessentialtothesuccessoftheprocess.

PartIII:IntroducetheProblemForbusinessesandindustriestobeprofitabletheyneedtomaximizeefficiency.Castfilmcomesinvariouscolorswithdifferingwidthsandthicknesses.Whenchangingworkordersthelineneedstopurgeandextracttheoldcolorandotheringredients.Thistakestimebutprocedureshavebeenimplementedtoincreasetheefficiencyofthechangeover.Theproblemisold“fluff”isgettingcaughtinthetubingorhopperandreleasingduringthesubsequentproductionorders.Forinstance,order#1isblackfilm,thoughorder#2willblue.Onoccasionthe“fluff”dislodgesandenterstheingredientsforthenextorder.Thiscausescolorringsandcreatesunneededorwantedscrapmaterial.

PartIV:BackgroundThestudentswillneedexplanationandexamplesofthecastfilmproductionprocess.Iwillalsoprovidehintsorcuesreferencingtheregrindprocessandreintroduction.I’mpresentingtheproblemverybroadlybecausetherearemultipleapplicablesolutions.Iwillincludeshortvideos,linkstocastfilmprocessing,andpictures.Withthisactivitytheproblemhasalreadybeenidentifiedandsolutionsactuallyarealreadyinplace.Iwantmystudentstoexaminemorethanwhatiscurrentlybeingusedtoremedytheproblem.Iwantthemtofindrootcausesoftheproblemandcomeupwithsolutionsthatceasethecreationofcolorrings.

PartV:BusinessSolutionThebusinesshasspentsufficientresourcestryingtominimizeanddiminishtheissue.Currentlynewequipmentisbeinginstalledtonegatethecolorringoccurrences.Also,engineersareresolvingplansandprocedurestoapproachthematterproactivelyinsteadofreactingwhensituationsarise.

PartVI:StudentSolutionsIthinkstudentswillcreatedevicesorsystemsthatpurgetheold“fluff”fromthetubes.Iimaginesomewilldevelopascrapertypeofasystem.Othersmayuseavacuumstylesetup.I’mhopingforawidearrayofsolutionsofvaryingtypes.

Name:BenKukerTeachingcontentarea(s):Tech.Ed.School:MtVernonCSDExternhostsite:AmericanProfol

ImprovingRegrindProcess