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1
BOWLING GREEN BOWLING GREEN STATE UNIVERSITY STATE UNIVERSITY
College of TechnologyCollege of Technology
TECH 626TECH 626 (Spring 2001)(Spring 2001)
2
TECH-626 TEAM TECH-626 TEAM PROJECTPROJECT
Phase-2 (final) Phase-2 (final) PresentationPresentation
LEC Rotational Molding Machine
Quality & Reliability
Assessment
3
TEAM MEMBERSTEAM MEMBERS
Steve GormleySteve Gormley
Diane PatinoDiane Patino
Chandana HewavitharanageChandana Hewavitharanage
INSTRUCTORINSTRUCTOR
Dr.J.W.Sinn Dr.J.W.Sinn (Professor-College of Technology, BGSU)(Professor-College of Technology, BGSU)
4
THE ROTATIONAL MOLDING THE ROTATIONAL MOLDING SECTION’SSECTION’S
CURRENTCURRENT OPERATIONS OPERATIONS
The Rotational Machine Operation Area The Rotational Machine Operation Area (pic 01)
5
The Rotational Molding MachineThe Rotational Molding Machine (pic 02)(pic 02)
THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont .cont .
6
The Rotational Molding Machine – cont.The Rotational Molding Machine – cont. (pic 03)(pic 03)
THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont .cont .
7
The Rotational Molding Machine - cont.The Rotational Molding Machine - cont. (pic 04)(pic 04)
THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont .cont .
8
The Rotational Molding Machine – cont.The Rotational Molding Machine – cont. (pic 05)(pic 05)
THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont . cont .
9
Molded LEC BodyMolded LEC Body
Molded Body
10
PRODUCT DESCRIPTIONPRODUCT DESCRIPTION
The Acme Lifeline Emergency Cart (LEC) is The Acme Lifeline Emergency Cart (LEC) is a fully functional crash cart designed from a fully functional crash cart designed from the ground up to meet the critical demands the ground up to meet the critical demands of a hospital “code.” A “code” is among the of a hospital “code.” A “code” is among the most critical of all hospital emergencies. most critical of all hospital emergencies. Efficient code response saves time and lives, Efficient code response saves time and lives, and that is where a LEC unit comes into and that is where a LEC unit comes into play.play.
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LEC’s FEATURESLEC’s FEATURES Quick, safe transport of vital supplies to the code sites.Quick, safe transport of vital supplies to the code sites. Simultaneous access by multiple code team members.Simultaneous access by multiple code team members. Self-contained vehicle, perfect for medical / surgical floors where Self-contained vehicle, perfect for medical / surgical floors where
vital equipment may not be readily available.vital equipment may not be readily available. Clear, logical organization and identification for all types of Clear, logical organization and identification for all types of
supplies.supplies. Convenience features include integrated backboard, gel bin and I. Convenience features include integrated backboard, gel bin and I.
V. bins.V. bins. Advanced design polymer materials are rugged, durable, yet Advanced design polymer materials are rugged, durable, yet
lightweight, rustproof and easy to clean.lightweight, rustproof and easy to clean. Fully enclosed unit with visible security checks.Fully enclosed unit with visible security checks.
12
PROBLEM STATEMENTPROBLEM STATEMENT Acme’s Lifeline Emergency Cart (LEC) assemblyassembly
line resembles a traditional batch and queue operation.
Due to competition and rising production costs, Acme is forced to implement new systems and approaches to increase productivity and quality at lower cost.
Team has selected Rotational Molding Machine operations, a critical area of current operations, and will present a proposal to improve quality and productivity.
13
OBJECTIVESOBJECTIVES Improve Safety and ErgonomicsImprove Safety and Ergonomics - Improve GSIC score by 90%- Improve GSIC score by 90% - Improve 5S Score by 425% to achieve 85% - Improve 5S Score by 425% to achieve 85% Improve QualityImprove Quality - Reduce scrap by 85%- Reduce scrap by 85%
- Determine Process Capability- Determine Process Capability - Redesign Product according to Process- Redesign Product according to Process Capability where neededCapability where needed - Improve Process Capability where needed - Improve Process Capability where needed (warp & shrink?)(warp & shrink?) - Achieve and maintain a minimum of 1.33 CPK of - Achieve and maintain a minimum of 1.33 CPK of all Critical to Quality Parametersall Critical to Quality Parameters
14
OBJECTIVES OBJECTIVES – cont.– cont.
Reduce Costs with new techniques
-Reduce scrap by 85% Acquire proper tooling
Develop Preventive Maintenance System
15
MAJOR STEPSMAJOR STEPS
1. Thorough data collection and analysis 1. Thorough data collection and analysis of Acme’s LEC Roto-Molding Machine of Acme’s LEC Roto-Molding Machine Station.Station. 2. Propose preliminary quality 2. Propose preliminary quality improvementsimprovements 3. Calculate Return on Investment 3. Calculate Return on Investment 4. Decide on proposed improvements4. Decide on proposed improvements 5. Develop training curriculum5. Develop training curriculum cont.cont.
16
MAJOR STEPS MAJOR STEPS (cont.)(cont.)
6. Detail Improvements6. Detail Improvements
7. Implement7. Implement
8. Feedback Analysis8. Feedback Analysis
9. Sustain9. Sustain
17
GENERAL GENERAL INDICATORS/ INDICATORS/
CHARACTERISTICSCHARACTERISTICS
Safety and Ergonomics:Safety and Ergonomics: Worker fatigueWorker fatigue Heavy toolingHeavy tooling Location of materialsLocation of materials Movements Movements Worker morale andWorker morale and overall safety through 5 “S”overall safety through 5 “S”
18
GENERAL INDICATORS/ GENERAL INDICATORS/
CHARACTERISTICS CHARACTERISTICS - -
contcont..Quality:Quality: Better finishing lookBetter finishing look Wastage of materialsWastage of materials Handling of productsHandling of products Workers knowledge in quality functions Workers knowledge in quality functions Worker morale in quality improvementsWorker morale in quality improvements Quality standardsQuality standards
19
GENERAL GENERAL INDICATORS/ INDICATORS/
CHARACTERISTICS CHARACTERISTICS
cont .cont .Reduce Costs :Reduce Costs : Recognizing non-value added processes and Recognizing non-value added processes and
eliminating them accordinglyeliminating them accordingly Reduction of materials wastages through proper Reduction of materials wastages through proper
handling and methodshandling and methods Better productivity levels to reduce unnecessary time Better productivity levels to reduce unnecessary time
through SOPsthrough SOPs (Quality Management)(Quality Management) Reduce defect rates through proper quality standards Reduce defect rates through proper quality standards
( Quality Management)( Quality Management)
20
GENERAL GENERAL INDICATORS/ INDICATORS/
CHARACTERISTICS CHARACTERISTICS – –
contd .contd . Decrease Cycle Time:Decrease Cycle Time: Wasted movementsWasted movements Poorly located toolingPoorly located tooling Unorganized work stationUnorganized work station
21
GENERAL INDICATORS/ GENERAL INDICATORS/ CHARACTERISTICS CHARACTERISTICS
– contd .– contd .Develop Preventive Maintenance: Develop Preventive Maintenance:
* Excessive trainingExcessive training
* Introduction of better PM * Introduction of better PM
methodsmethods
* Introduction of Preventive * Introduction of Preventive
Maintenance Management Maintenance Management
SystemsSystems
22
STATISTICAL ANALYSISSTATISTICAL ANALYSIS
0.1600.1550.1500.1450.1400.1350.1300.1250.1200.1150.110
20
10
0
C2
Fre
qu
ency
Finger Guard Wall Thickness - "B" Zone
23
STATISTICAL ANALYSIS STATISTICAL ANALYSIS CONTD.CONTD.
0.180.170.160.150.140.130.12
15
10
5
0
C3
Fre
qu
ency
Finger Guard Wall Thickness - "C" Zone
24
STATISTICAL ANALYSIS STATISTICAL ANALYSIS CONTD.CONTD.
0 10 20
0.140
0.145
0.150
0.155
Xbar and R Chart
Subgr
Me
an
1
Mean=0.1464
UCL=0.1556
LCL=0.1371
0.00
0.01
0.02
0.03
Ra
nge
1
R=0.01605
UCL=0.03395
LCL=0
0 10 20
Last 20 Subgroups
0.13
0.14
0.15
0.16
Subgroup Number
Va
lue
s
0.1 0.2
Capability PlotProcess Tolerance
I I I
I I I
I ISpecifications
Within
Overall
0.13 0.15 0.17
Normal Prob Plot
0.12 0.14 0.16
Capability Histogram
WithinStDev:Cp:Cpk:
0.00690232.412.24
OverallStDev:Pp:Ppk:
0.00699762.382.21
LEC Finger Guard Wall Thickness - Area A
25
STATISTICAL ANALYSIS STATISTICAL ANALYSIS CONTD.CONTD.
20100
0.15
0.14
0.13
0.12
Xbar and R Chart
Subgr
Me
an
Mean=0.1333
UCL=0.1490
LCL=0.1175
0.06
0.04
0.02
0.00
Ra
nge
R=0.02726
UCL=0.05764
LCL=0
20100
Last 20 Subgroups0.155
0.140
0.125
0.110
Subgroup Number
Va
lue
s
0.20.1
Capability PlotProcess Tolerance
III
III
IISpecifications
Within
Overall
0.1500.1250.100
Normal Prob Plot
0.1500.1250.100
Capability Histogram
WithinStDev:Cp:Cpk:
0.01171991.420.95
OverallStDev:Pp:Ppk:
0.01205511.380.92
LEC Finger Guard Wall Thickness - Area B
26
STATISTICAL ANALYSIS STATISTICAL ANALYSIS CONTD.CONTD.
20100
0.16
0.15
0.14
0.13
Xbar and R Chart
Subgr
Me
an
1
Mean=0.1436
UCL=0.1593
LCL=0.1279
0.06
0.04
0.02
0.00
Ra
nge
R=0.02719
UCL=0.05749
LCL=0
20100
Last 20 Subgroups0.18
0.16
0.14
0.12
Subgroup Number
Va
lue
s
0.20.1
Capability PlotProcess Tolerance
III
III
IISpecifications
Within
Overall
0.1700.1450.120
Normal Prob Plot
0.1700.1450.120
Capability Histogram
WithinStDev:Cp:Cpk:
0.01168981.431.24
OverallStDev:Pp:Ppk:
0.01224941.361.19
LEC Finger Guard Wall Thickness - Area C
27
APPLICATION FORMSAPPLICATION FORMS1.1. RCA:RCA:
OPAQAFL/ IRAA / TAA/ TPMA/ TPMAF/ OPAQAFL/ IRAA / TAA/ TPMA/ TPMAF/ OBACDSOBACDS
2.2. SDA :SDA : MMA/ GSIC /GWSC /PC MMA/ GSIC /GWSC /PC /CA/FMEA/ 5S Program/ Cause and Effect /CA/FMEA/ 5S Program/ Cause and Effect Diagram / CI/ ITC/ Diagram / CI/ ITC/ CA/VSRC/CTTIC/VSRCCA/VSRC/CTTIC/VSRC
3.3. RCA:RCA: TPMA/TPMAF/OBACDSTPMA/TPMAF/OBACDS
28
TEAM EVALUATIONTEAM EVALUATION
Quality of the weekly postings has been Quality of the weekly postings has been improved.improved.
On-line meetings took more organizedOn-line meetings took more organized approach with the beginning of approach with the beginning of phase 2. phase 2. Timeliness was not improved due to various Timeliness was not improved due to various
reasons.reasons. Good team approach and team work.Good team approach and team work.
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TEAM’S CURRENT TEAM’S CURRENT GOALSGOALS
Apply the suggested and developed ideas with Apply the suggested and developed ideas with appropriate techniques to the Current appropriate techniques to the Current Operations in the manufacturing process.Operations in the manufacturing process.
To complete the phase 2 as best as possible.To complete the phase 2 as best as possible. Once Completed, Publish the Project in a Once Completed, Publish the Project in a
Recognized Academic or Professional Journal.Recognized Academic or Professional Journal. ( in this regard already arranged the necessary ( in this regard already arranged the necessary
steps) steps) To Obtain a “ A” Grade for the TECH 626.To Obtain a “ A” Grade for the TECH 626.
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The EndThe End
31
We, 2001 (spring) TECH We, 2001 (spring) TECH 626 team, take this 626 team, take this
opportunity to thank opportunity to thank Dr. J .W. SinnDr. J .W. Sinn
for his guidance, for his guidance, encouragement, encouragement,
numerous helps, and numerous helps, and flexibility we have been flexibility we have been
receiving since the receiving since the beginning of this coursebeginning of this course..
32
Thank Thank YouYou
Please see the attached phase 2 Please see the attached phase 2 file file
(final draft) for more details.(final draft) for more details.