Enhancing Resource Availability in the Wire Harnessing ... · High performance assembly jig • Used to install rubber door seal onto frame • ULTEM 9085 and Nylon 12 with integrated

Enhancing Resource Availability

in the Wire Harnessing

Department for FORCE America

KaytLynn Riel

Milwaukee School of Engineering

August 29th, 2018

Agenda

Background

Problem

Data Collection

Improvement Alternatives

Recommendation

Company Background

FORCE America was Founded1953

Electrical Division In-House1992

Project Background

Production Schedule

Job Packets

Tooling

Problem Statement

Scheduling

with PriorityResource Sharing

Scope

Develop Baseline Metric

Examine Tooling

Capacity

Understand Production

Scheduling Factors

In S

co

pe

Ou

t o

f S

co

pe

Product Design

Examine Wire

Storage Area

Product Quality

Data Collection and Analysis

Resource Availability Study

MPX Model

Production Scheduler Interview

Data Collection and Analysis Continued

Resource Availability Study

1.83 Shares per Shift

Record Time Waiting

or Sharing Tools

183.4 Harnesses in

Lost Production a Year

Project Objective

1.83

0.50Shares per Shift

Shares per Shift to

Information Collection:

9 Product and Tool Families

37% Wire Harness Demand

MPX Model

Key

App Applicator

HT Hand Tool


Scheduling with Tooling

Environment MachineMan

Software

Excel

AX

Hard to Tell Who has What Tool

Walking Required for Equipment Retrieval

Slow Production PaceProduction Lead for Wire

Harnessing

Production Scheduler for Wire Harnessing

Process Time Accuracy

Tooling at Stations are not Used 100% of the Time

Hand Tools

Required Tooling Visibility

Harness Number

Business Add-On

Job Packet

Floor Scrap

Manufacturing Floor

Schedule Similar Products at the Same Time

Change Schedule Multiple Times a Day

Assemblers in Wire Harnessing

Applicators

Job Packet

Production Scheduler Interview


Improvement Alternatives

Schedule Generator with Tooling

Real-Time Production Schedule

Digital Note Sheets

Digital Work Instructions

Improvement Alternatives Continued

Item Value

Initial Cost $ 4,880

Annual Benefit $ 8,452

Interest Rate 9%

Payback Period 7.43 Months

Features

Identify Tooling Required

Auto-Organize Tooling Based on

Priority

Benefits

Reduce UnnecessarySetup Time

Reduce Sharing to 0.5 Shares

per Shift

Costs

Program Development

Training

Schedule Generator

with Tooling


Features

Auto-Update Production

Schedule on Floor

Identify Available Tooling for Production

Benefits

Reduce UnnecessarySetup Time

Reduce Sharing to 1.0 Shares

per Shift

Costs

Program Development

Barcode Scanner

Item Value



Interest Rate 9%


Real-Time

Production Schedule


Features

Electronic Data Record

Improve Data Access for Employees

Reduce Paperwork Scanning

Costs

Program Development

Computer Components for

Each Cell

Item Value


Annual Benefit $ 650

Interest Rate 9%

Net Present Value $ (1,831)

Digital Note Sheet

Benefits


Digital Work

Instructions

Features

Interactive Work Instructions

Improve Data Access for Employees

Benefits

Reduce Paperwork Scanning

Reduce Unplanned Labor Cost

Costs

Program Development

Computer Components for

Each Cell

Item Value



Interest Rate 9%


Recommendation

Schedule Generator

with Tooling

Recommendation Development

Enter Production Information

See Results with

Conflicts

See Results in Gantt Chart

Thank You!

PRESENTED BY

VSA Partners

CONFIDENTIAL

StratasysThe Power of Additive. Applied.

Factory Floor Solutions

July 2018

The Power of Additive. Applied.

21

Common applications

• Assembly fixtures

• Check gauges

• Surrogate parts

• Protective covers

• Tool organizers

• Part cradles

• Forming tools

• Drill jigs

• Badge alignment fixtures

• End of arm tooling

• Ergonomic handles

• Replacement parts

• CMM fixtures

Additive Manufacturing on the Factory Floor

22

Additive Manufacturing on the Factory Floor

LEAN Manufacturing

• Eliminating Waste

• Continuous Improvement

• 5S

Ergonomic Design

• Productivity

• Safety

Total Productive Maintenance

• Uptime

• Cost savings

23

• Eliminating waste

Additive is FLEXIBLE. It is applied throughout the value stream to speed production, improve quality and minimize downtime

• Continuous improvement

Additive is FAST. It improves flow through the factory by allowing quick iterations of your solutions

• Organizing workspaces

Additive is FIVE S. It allows for infinitely customizable workspaces insuring the right parts and tools are quickly and safely accessible

LEAN Manufacturing

ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.

24


LEAN Manufacturing

High performance assembly jig

• Used to install rubber door seal onto frame

• ULTEM 9085 and Nylon 12 with integrated

components produced a tool that was over

100 pounds lighter than predecessor

• Allowed for a 4 second per cycle decrease,

with over 250,000 cycles per year

25


LEAN Manufacturing

Rubber tube clamp for nitroglycerin

• Old ball valve design was easily

contaminated and needed to be replaced

frequently

• After two iterations, the tool works great

• Only Stratasys Nylon12 CF had the

strength required to print this clamp

26


LEAN Manufacturing

Inspection tool for auto air conditioner

• Fixture to validate production part in

South Korea

• Printed in ASA, combining strength,

aesthetics and durability for the

application

• Tool needed to be designed, printed and

shipped within one week, vs 4-5 weeks

for CNC

• Lighter and $1000+ less expensive than

CNC machined fixture

27


LEAN Manufacturing

Angled splitter bung machining fixture

• Fixture allows for small holes to be

clocked in various positions

• Relatively high volume engine part

needed repeatable and reliable process

• Simple additive fix to complex machining

problem

28


LEAN Manufacturing

5S shadow board

• Machine specific tools readily available

• Small improvements can provide big

savings

• Flexibility to change for new parts or

operations

29

Ergonomic Design

Workplace injuries cost US manufactures over $62B annually.

Overexertion is the number one cause of injuries accounting

for over 25% of this cost - 2016 Liberty Mutual Workplace Safety Index

• Engineered materials

Additive can replace metals in many applications, reducing weight and improving quality and safety

• Design for additive

DFAM allows for designs with strength just where it is needed

• Human factors

Tooling can be custom fit to operators of different sizes, abilities and hand dominance

With the design freedom of Additive Manufacturing and Stratasys materials, tooling can be LIGHTER WEIGHT and ERGONOMICALLY DESIGNED resulting in improved processes and fewer injuries

30


Ergonomic Design

Torque verification and connector

adapters

• Existing process was causing injuries

and affecting worker morale

• Connector adapter took 3 hours to create

from initial measurement to

implementation

• Torque verification puck improved

throughput and operator satisfaction

31


Ergonomic Design

Rocker lever spring compressor

• Pneumatic compressor tool with printed

handle, guard and structure

• Previous operation required two

operators

• Printed tool reduces safety risk and

improves quality

32


Ergonomic Design

Conductive pick handle

• Existing tool was difficult to use

• Assemblers modified tool with

Moxi tape

• New 3D printed tool designed

to fit hand

• 100s printed to meet assembler

demand

33


• Virtual inventory

• Reduced number of vendors

• Shorter lead times

• No minimum order quantities

• Just-in-Time, not Just-in-Case

Additive manufacturing can provide direct replacement parts and process improvements for the most demanding industrial applications

34



Wrapping machine replacement part

• Mis-fed would cause downstream damage on

machine

• Replacement metal part had long lead time

• Printed part is 83% less expensive and takes 49

minutes to print

• Part was designed as a mechanical fuse to

prevent downstream damage

35



Hydroforming tool

• Emergency landing caused damage to a single

stringer in the nose which had impacted the table

• Rather than ordering from an OEM or

remanufacturing the part, they designed a set of

doublers as structural reinforcement

• Forming tools were printed overnight in PC

• Parts were formed that same week via

hydroforming

• Aircraft was back in service within 1 week

36

Dimensionally correct parts the first time, every time.

• Print confidence means greater machine uptime

• Easy to use requiring less engineering and operator labor

• Production grade system for years of reliable service

Over 30 years of expertise.

• Application knowledge

• Design for additive

• Software that secures design intent

More materials. Better solutions.

• Leader in additive formulations

• ABS, ASA, PC, Nylon12CF, Ultem,…

Why STRATASYS?

37

Identify pain points / Opportunities

• Visual factory boards

• Kaizen events

• Daily stand-up meeting

• Factory walkthroughs

Engage / educate

• Local manufacturing engineers / tooling designers

• Stratasys AEs

Implement

• Plan Do Check Act

• Document benefits and scale

Implementing Additive on the Factory Floor

Wayne BensonDirector, Factory Floor [email protected]

mailto:[email protected]

Documents

Enhancing Resource Availability in the Wire Harnessing ... · High performance assembly jig • Used to install rubber door seal onto frame • ULTEM 9085 and Nylon 12 with integrated