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Design Optimization for Dadant Product Work CellsBridgeway | Group #2
Students: Arielle Anderson-VenerableJordan PalmerKelsey Schreiber
Advisor: Prof. Sewoong Oh
Contact: Tammy DiefendorfScott TeelBrittany Aten
1
OverviewBridgeway Introduction
Dadant & Sons
Assembly Tasks
Problem Statement
Objectives
Air Flow and Drying Options
Systematic Layout Planning
Line Balancing Analysis
Economic Analysis
Conclusions and Recommendations
Q & A
2
“Creating Solutions for Everyone.”
Affirmative Employment ServicePhysical and/or mental disabilities
Consumer vs. Productionist
Contract Work Dadant & Sons -- Beekeeping Supplies
3
Production Overview
Final Assembly and Packaging
4
Frame Production
Hive Body Production
Shipping Box Construction
Frame Production (1 of 2)
5
Frame Production (2 of 2)6
Hive Body Production (1 of 3)
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Hive Body Production (2 of 3)
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Hive Body Production (3 of 3)
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Final Assembly and Packaging
10
Problem StatementImprove efficiency of facility layout
Reduce non-value added work & work in process
Decrease drying time for painted/primed hive bodies
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Objectives
Conduct time studies
Use Systematic Layout Planning (SLP)
Line Balancing Analysis
Establish and improve paint/primer drying time
Conduct economic analysis
Recommend improvements
12
Paint Drying - Current State13
Primer Paint
Bridgeway Estimate 175 min - Overnight* 55 min - Overnight*
Label Estimate 60 min 60 min
*Current drying time highly variable due to environmental conditions.
Paint Drying - Environmental Improvements Move drying into paint room
Temperature Control
Dehumidifier
Air Ventilation
14
[Ivation 2016, Vornado 2016]
Paint Drying - Systematic Improvements
● Digital/Kitchen Timers● Dry Erase Time Notation● Time Stamp Labeling
15
[Amazer 2016, Cosmos 2016, Demarkt 2016]
SLP- Introduction
Quick material flow
Less WIP
Reduced handling
Subjective -> objectiveFlowPlanner
16
[Muther 1973]
SLP- Flow Planner Initial Analysis17
● Product/Part Routes Mapped in AutoCad● Routes along Aisles● Wage and Walking Speed along paths● Aggregate per Monthly production
SLP - AEIOUX Analysis18
SLP - Design and Analysis Phase Used AEIOUX to guide design of new layouts
Maximize A, E, and I relationships
Analyze layouts in FlowPlanner
19
SLP- Consulting with Bridgeway
● Selected layout 4● Not most Efficient but…
○ Sound Accommodations
20
SLP - Layout Implementation
21
Balance workload among workstations
Decrease Idle Time
Decrease work pile-ups
22
Line Balancing- Introduction
Line Balancing- Unique Challenges
Typical Line Balancing
Involves assigning different tasks to same workstation or worker to balance workload
The Challenge
Consumers and Productionists are limited to very specific tasks based on abilities
23
Line Balancing- Typical Method24
● A new unit enters next workstation every 15 minutes● Number of tasks/worker varies
Line Balancing- Alternative Approach
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● A new unit enters the next workstation every 5 minutes● Number of workers/task varies
Line Balancing- Precedence Diagram
26
Must happen 10 times before next step:Total Time = 8.7 minutes
Line Balancing Summary
66% consumer employment increase
Minimum Cycle Time: 2.31 minutes
Constraint: Hive Body Construction
27
Economic Analysis
Initial Cost: $1,629.00
Monthly Savings: $2,593.00
Monthly Recurring Costs: $24.00
Payback Period: 19 days
Monthly IRR: 155%
Yearly IRR: 1633%
28
Economic Analysis- Supply Increase
97 bodies per day → 2143/month
Current average: 1664/month
Revenue increase: $2,933.00Total increase: $5,526.00
54% increase in average hive body revenue
29% increase in product throughput
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ConclusionsLoss of profit each month due to
layout
Hive body drying process is long
Bridgeway's supply from Dadant is inconsistent
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RecommendationsDesign
Drying Room
Dadant supplies
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Questions?
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Option #1
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Option #2
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Option #3
35
Option #4
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Option #5
37
Budget/Economic Analysis
Grant-based funding
Non-profit organization
Previous work with Dadant & SonsNon-standard payment setup
Short-term loss for long-term success
Supply restrictions
38
Project Constraints
There are some constraints that the project team must account for, including: 1. Tasks, and how they are completed, must remain the same. Both consumers and
productionists are trained by an outside team, and restructuring training and specific tasks is not an option.
2. Productionists must complete all steps involving the movement of materials around the plant.
3. Frame stapling and box hammering must be kept away from the office as they interfere with communication.
4. Stapling equipment is not owned by Bridgeway, and thus is not eligible for possible design updates.
39
Flow Planner - Aisle Routes (Large Hive Bodies)
40
Flow Planner- Direct Paths (Large Hive Bodies)
41
Flow Planner- Configuration,1 (Large Hive Bodies)
42
Flow Planner- Configuration.2 (Large Hive Bodies)
43
“Creating Solutions for Everyone.”
Est. 1993
Affirmative Employment ServicePhysical and/or mental disabilities
9000 people employed/served per year
Contract Work
44
Project Location | Macomb, IL.
45
Production Areas
Storage
Storage
StorageArea
Air Flow/Drying
46
Space for Temporary Jobs
47
Work in Process
48
Drying Room Stairs
49
Project Gantt Chart50
Work Flow51
SLP - Noise Constraints52
ISO Certification
Provide guidelines that can be used consistently to ensure that materials, products, processes and services are fit for their purpose
21000+ standards (for purchase)
Ensure products and services are safe, reliable, and good quality
Reduce costs by minimizing waste and errors, and increasing productivity
53
[ISO.org]