Team MembersStefan Enjem – ISE

Joe Van Hofwegen - ISEYoung Lee - ISEJoe Pecht - ME

Walter Freitag - MEJason Zion - MELuis Garcia - EE

IEIE

MEMEEEEE

Hydraulic Fan Motors

Who uses them? Why are they used? How are they built?

Needs Assessment

QPH (9)4 to 6% Increase in Production2 year paybackSafety and Quality

Organization

Scope and Resource DistributionWork Breakdown Structure

SchedulingGantt Chart

CommunicationYahoo Web Group

Deliverables

Standardized Procedures

Preventative Maintenance

Set Production Guidelines

Fix Problematic Stations

End of Line Tester Efficiency

Identify improved system configurations

Organizational Structure

Project ManagerStefan Enjem

ProceduresJason Zion

Problem Stations

Joe Pecht

EOLTWalter Freitag

Simulation Joe VH

Data AnalysisYoung Lee

ControlsLuis Garcia

Data Collection and Analysis

Data Collection

Motor Counters

EOLT Data Sheets

Cycle Time

Historical Data

Bottleneck Identification Histogram shows major sources of backup

0

10

20

30

40

50

60

90 100

110A

110B

120A

120B 13

0

140A

140B

150A

150B 16

0

170A

170B 18

0

190

200A

200B 20

5

210

230A

230B

EO

L

Station

Cy

cle

Tim

e (

se

co

nd

s)

Direction of Assembly

Manual

Automated

Micro-stop

Micro stop = Downtime of less than 5 minutes

0

50

100

150

200

250

300

350

400

450

Station 210 Station 140 Station 230 Station 200 Station 170

Station

Freq

uenc

y of

Mic

rost

op

(app

rox

6 w

eeks

)

Cumulative Sum

Industrial Standards

Clean RoomCertified Class 100,000

QS 9000Quality standard TS 16949

Valeo Union Standard423 minutes per shift

Ergonomic Guidelines

Detailed ProceduresStandard Procedures

Worker Rotation Failure Response Plan

Manual Stations

Current Problems

Concept for Improvements

Expected Improvements

Station 90 Station 160

Preventative Maintenance

Creation of a Preventative Maintenance Schedule

Station 210

• Current ProblemsCamera for Optical Test

Leak Test Connectors

•Concepts for Improvement–Mirror

–PM on Rubber Connectors

•Expected Improvements–Reduction in Downtime

Rubber Connectors

Station 210

End of Line Tester

Function Current Problems Feasibility of

Concepts

Mounting Concept

Linear Slide Mount

Mating Concept

Modified Assembly Cell Balancer

Technical Analysis

FEA Air Cylinder Sizing Expected

Improvements

Arena Simulation – Our Test Plan

Analyze system as a whole Identify optimal system configuration and

alternatives Using pallets, conveyor speed, queue sizes

Justify Improvements

Qualifier Improvement Winner Improvement4% 8%

Cost Analysis of Total System

Improvement Cost OT Saved (After 2yrs)Total 61,347.00$ 157,831.80$

• Estimated Cost Analysis

Interest Rate 5%

Total Cost ($61,347.00)Return After 1 Year 78,915.90$ Return After 2 Years 157,831.80$

Net Present Value $81,323.85

• Net Present Value

Future of Project Engineering Models Head start

Simulation Stations

Detailed Design Meet the Goal

Backup - Bill of Materials Bill of Materials*

Station Part # Quantity Unit Description Production

Board 518936 1 Each 3' by 5" Dry erase Board

1 Each 1foot of stock aluminum 2 Each Machined steel block to hold marker cap Station 160 3 Each Bracket Hardware to support cap holder

INRD-50 1 Each DVT Doal light source, 50mm

INOO-S12 1 Each DVT Doal light source Power Supply Station 210 1 Each Rubber connector

- - Required Mounting Hardware

EOLT FO-501.500 4 Each Bimba Pnuematic Air Cylinder 2 Each Custom Motor Mounting Plate 2 Each Custom 1/2" Motor Mounting Bracket 2 Each Custom 3/4" Motor Mounting Bracket 2 Each Custom 1" Motor Mounting Bracket

MM-C

6498K266 6 Each Spring-Return Pivot-Mount Cylinder --------- 2 Each Press Fit Connector Assembly 2 Each Custom Connector Base Plate 2 Each Custom Connector Plate - - Required Hydraulic/Pneumatic Plumbing - - Require Mounting Hardware

5 Each EDI Digital counters Timer

5 Each EDI Mounting brackets for timer * Tentative Bill of Material Station 90: Cavalry Automation Systems has been awarded the contract to implement The improvements being made to this system at a cost of $6,910.

Backup - RegressionManpower vs. Motors Out

y = -10.49x2 + 107.09x + 35.586R2 = 0.4265

0

50

100

150

200

250

300

350

400

450

500

1 2 3 4 5 6 7 8

Manpower

Mo

tors

Ou

t

Manpower vs. QPH y = 1.8564x2 - 30.104x + 160.97

R2 = 0.5938

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

0 1 2 3 4 5 6 7 8

Manpower

QP

H

Backup – Bottleneck RankBottleneck Ranks

Rank Station Avg Cycle Time

1 EOL 44.07

2 90 36.93

3 160 35.48

4 100 22.18

5 170A 21.17

6 140A 20.85

7 200B 20.80

8 110B 20.50

9 120B 19.66

10 210 17.71

11 140B 17.20

12 180 16.85

13 205 16.69

14 120A 15.86

15 150B 15.07

16 190 15.01

17 200A 14.94

18 110A 14.88

19 150A 12.95

20 170B 11.65

21 230B 11.48

22 230A 10.78

23 130 6.29

Backup - WBS

Backup –Gantt Chart

Backup – Counter DataMotor Count Log

Date Shift Motors

Out

Motors Back

In Total Manpower QPPH

1/26/03 B 54 4 50 2 3.55 1/27/03 A 237 0 237 7 4.80 1/27/03 B 246 1 245 2 17.38 1/28/03 A 280 2 278 7 5.63 1/28/03 B No Info No Info 1/29/03 A 172 3 169 6 4.00 1/29/03 B 210 2 208 2 14.75 1/30/03 A 310 3 307 5 8.71 1/30/04 B 234 1 233 2 16.52 1/31/04 A 121 1 120 4 4.26 2/1/04 A 94 1 93 4 3.30 2/1/04 B No Info No Info 2/2/04 A 245 3 242 7 4.90 2/2/04 B 90 2 88 1 12.48 2/3/04 A 322 5 317 7 6.42 2/3/04 B 138 5 133 2 9.43 2/4/04 A 400 4 396 7 8.02 2/4/04 B 163 3 160 2 11.35 2/5/04 A 432 3 429 7 8.69 2/5/04 B 151 5 146 2 10.35

Average 216.61 2.67 213.94 4.22 8.59