Process Analysis and Design Improvement of a Heavy Duty Electric

Actuator at Governors America

By: Anthony MoneAnd

Michael Butt Advisor: Dr. Abdul

Kamal

Overview

Brief Company HistoryProblem StatementSolution ApproachDeliverablesInitial WorkFuture WorkQuestions

Governors America Corp. Privately owned corporation, founded in 1986.

Resided originally in downtown Springfield until it moved to Agawam, MA in 1991 due to an increase in profit and production.

GAC’s Quality Assurance Group has established and implemented a quality system that complies with the directives of ISO9001 standards.

Currently the company is generating annual revenue of $12,000,000 controls roughly 60% of its market.

Problem Statement

Develop an accurate process sheet for every operation and evaluate and improve the current 176AA actuator production line

Reduce costs of production, waste, and takt time Increase throughput and improve quality

Governors America Corp. currently has no process sheets for the 176AA actuator production line. These process sheets will be beneficial to setting a standard to reduce variability in production. Once completed, the production line will be analyzed and improvements made.

Solution ApproachesCreating Process SheetsDevelop StandardsDevelop Flow ChartsDetermine DefectsApply Lean ManufacturingAnalyze Production Safety and Ergonomic

IssuesSimulate the Production Line

Deliverables

Current and accurate process plans for the 176AA actuator

Accurate time standardsReduced WIPReduced waste and defectsDecrease cost Increase throughput

Initial WorkDocumented processes via digital imagery and

video recording for use in writing process sheets.

Created rough schedule for first semester.Developed flow chart.Begun to look at machining draft of assembly

housing, to design inspection fixture.Developed crude simulation, based on

standards projected in routing sheets.

Flow ChartOp. 5

Wind ColdStart Coil

Op. 6Assemble Cold

Start Coil toCoil Housing

Op. 7Pot Cold StartCoil Assembly

Op. 8Face and Paint

Cold Start

Op. 10Potting

Op. 20Clean

Op. 30Bearing/Arm/

ShaftAssembly

Op 40ConnectorAssembly

Op. 45Mechanical

Asembly

Op. 50Bracket/Lever/

ShutoffAssembly

Op. 60Test

Op. 70Cover

Assembly /Date Stamp

Op. 80Product Audit

Op. 90Labels

Op. 100Final

Inspection

Op. 110Packing

First Semester Schedule

ID Task Name Duration Start % Complete Finish

1 Initial trip to Governors to setup project 1 day Tue 9/23/03 100% Tue 9/23/032 Trip to Governors 1 day Fri 9/26/03 100% Fri 9/26/033 Define problem 1 day Fri 9/26/03 100% Fri 9/26/034 Become aquainted with 176AA line 1 day Fri 9/26/03 100% Fri 9/26/035 Determine what needs to be done next time1 day Fri 9/26/03 100% Fri 9/26/036 Create Process Plan 46 days Fri 10/3/03 39% Fri 12/5/037 Trip to Governors 1 day Fri 10/3/03 100% Fri 10/3/038 Obtain BOM 1 day Fri 10/3/03 100% Fri 10/3/039 Obtain Traveler to define steps in process1 day Fri 10/3/03 100% Fri 10/3/0310 Get schematics for the 176AA actuator1 day Fri 10/3/03 100% Fri 10/3/0311 Take photographs of parts 1 day Fri 10/3/03 100% Fri 10/3/0312 Trip to Governors 1 day Thu 10/9/03 100% Thu 10/9/0313 Talk to Beth about a work space 1 day Thu 10/9/03 100% Thu 10/9/0314 Try to get a plant layout 1 day Thu 10/9/03 100% Thu 10/9/0315 Take photographs of parts 1 day Thu 10/9/03 100% Thu 10/9/0316 Trip to Governors 1 day Fri 10/17/03 100% Fri 10/17/0317 Take photographs of parts 1 day Fri 10/17/03 100% Fri 10/17/0318 Trip to Governors 5 days Fri 10/24/03 46% Thu 10/30/0319 Finish taking pictures 1 day Fri 10/24/03 100% Fri 10/24/0320 Start learning/ video taping the process1 day Fri 10/24/03 100% Fri 10/24/0321 Start writing Process Plan 5 days Fri 10/24/03 25% Thu 10/30/0322 Trip to Governors 5 days Fri 10/31/03 17% Thu 11/6/0323 Learn/ videotape more of the process 1 day Fri 10/31/03 100% Fri 10/31/0324 Write Process Plan 5 days Fri 10/31/03 0% Thu 11/6/0325 Trip to Governors 5 days Fri 11/7/03 17% Thu 11/13/0326 Learn/ videotape more of the process 1 day Fri 11/7/03 100% Fri 11/7/0327 Write Process Plan 5 days Fri 11/7/03 0% Thu 11/13/0328 Trip to Governors 9 days Fri 11/14/03 10% Wed 11/26/0329 Learn/ videotape more of the process 1 day Fri 11/14/03 100% Fri 11/14/0330 Write Process Plan 9 days Fri 11/14/03 0% Wed 11/26/0331 Trip to Governors 1 day Fri 12/5/03 65% Fri 12/5/0332 Finish Time Studies 1 day Fri 12/5/03 65% Fri 12/5/0333 Write Project Proposal 1 day? Mon 12/1/03 100% Mon 12/1/0334 Finish Project Proposal Power Point 10 days? Mon 12/1/03 100% Sun 12/14/03

21 24 27 30 3 6 9 12 15 18 21 24 27 30 2 5 8September 2003 October 2003 November 2003

ABET

Manufacturability Health and Safety Economic ConcernsSustainability Ethical Concerns

Future Work

Start to write process sheets from video recordings.

Perform time studies.Identify most value added operation for

starting point for improvement.Determine defects of production

Questions?