Terumo Cardiovascular Systems:Oxygenator Production Improvement

University of Delaware’s Senior Design Team:Tom Craig

Mike GiulianoRonit Lilu

Chase RossKate Staley

Description of Project

• Project Goals:– Improve the efficiency of

Reservoir Assembly production line via reduction in downtime, change over time, and cycle time.

– Employ lean manufacturing techniques from the ground up such as participation in a Kaizen event

Assembly Line

Lid Assembly VR Station CR StationReservoir Inspection

Leak Tester

Final Assembly

CR

VR

Lid

Jig

Lid Line

Current Floor Layout vs. Future Floor Layout

CR

Lid Line Assembly Table

Reservoir Assembly Table

VR

Product Flow

Lean Manufacturing Techniques

• The Kaizen event:• Attended a meeting with representation from operators,

manufacturing, production supervisors, engineering, and plant leadership to discuss improvements

• Time study• Spaghetti diagrams• Value Stream Mapping (VSM)

– Value Added, Non-Value Added Time

Customers & Wants• Customers: Terumo Management, Terumo’s Floor Staff, Surgeons, Hospitals,

Patients

Metrics and Target Values

Metrics Target ValuesAccuracy of Manufacturing/Error Proof 100%

Harmful Factors3 feet egress clearance, limit body rotation/twisting/reaching, adjustable table heights for ergonomics

Minimize Space VR Table 3 ft or less, CR Table 2’ x 2’

Waste of Time less than 20%, less than 1 mile/day walking

Cycle Time reduce by 4 sec (from 42 sec to 38)

Productivity Increase of 675 units of oxygenators/week

Risk Score below 25 RPN (no mitigating action required)

Current Floor Layout vs. Future Floor Layout

CR

Lid Line Assembly Table

Reservoir Assembly Table

6 Passes of 3 Steps Each

1 Pass of 3 Steps

VR

Product Flow

-VR walking distance/day ≈ 6.6 miles-CR walking distance/day ≈ 1.5 miles

-VR walking distance/day ≈ .5 miles-CR walking distance/day ≈ 0.3 miles

VR: Current State vs. Future

Current State Future State

Time Saved: mostly due to table redesign and offline productionWalking Time - 6.3 seconds

VR Concepts• Rotate lid assembly table and

align it with Chemical Table• Redesign Chemical Table and “L”

it with the assembly line• Design and manufacture

additional jig• Take wings off jigs on table• Sensors on bins to force order

CR: Current State vs. Future State

Current State Future State

Time Saved: 9.9 seconds reduced time through elimination of walking (moving caps) and addition of the chemical sensor.Note: Increased VA time due to addition of inspection tasks

CR Concepts• Move caps down to reservoir

inspection• Time sensor for chemical

dipping• Move CR cart closer to

operator• Increase inspection duties

Reservoir Inspection: Current State vs. Future State

Current State Future State

Reduction in Inspection DutiesLine Balancing: Additional responsibilities (placement of 6 more caps)

Proposed Floor LayoutTable at VR StationTable at CR Station

Final VR Table

Large tubes

Small tubes

Fume hood

TricotsDrainage cages

Jig

Position forcing tray

Preparation before Implementing

• Risk Analysis– Met with a team of Terumo associates including

engineering, upper management, quality manager, and manufacturing associates to assess risk via a Terumo Risk Analysis template.

– Given GREEN light to go ahead

• Update Standard Operating Procedures– Drafted changes to the SOP via text and pictures

which was then reviewed and approved by Terumo

Implementation/Testing

• Off-line implementation– Operator at Terumo

tested the new set-up of VR table on manufacturing floor to make sure everything easy to reach and functions well.

Implementation/Testing

Parts in bins Current Future

Large Tubes 60 110

Small Tubes 80 160

Drainage Cages

45 28

Tricots 100 60

• Parts were loaded into bins to test how much they hold.

• Improvements:• Tricot and drainage cage bin

sizes increased to increase capacity

• Positioning adjustments made

Performance MetricsMetrics Target Values Actual ValueAccuracy of Manufacturing/Error Proof

100% Determined in Path Forward

Harmful Factors3 feet egress clearance, limit body rotation/twisting/reaching

3 ft. egress clearance met, eliminated rotations/twisting/reaching

Minimize Space VR Table 3 ft or less, CR Table 2’ x 2’

VR Table 3’x 2.5’,CR Table 2’ x 2’

Waste of Timeless than 20%, less than 1 mile/day walking

VR = 0.5 miles/dayCR= 0.3 miles/day, less than 20% waste achieved

Cycle Time reduce by 4 sec (from 42 sec to 38)

Cycle Time in Path Forward expected to meet 38 sec requirement

Productivity Increase of 675 units of oxygenators/week

675 units of oxygenators/week expected to be met in Path Forward

Risk Score below 25 RPN (no mitigating action required)

Risk slightly increased but significantly under 25

Path Forward

• Terumo will manufacture the new bins for the increased capacity and new arrangement.

• Design can then be implemented on the line.• Additional time studies and spaghetti diagrams are

recommended once implemented on the line.• Sensors will be implemented at a later date by

Terumo.

Project Cost

Item/Material Cost

CR Table $411

VR Table $468

Jig (block of Delrin) $262

Sensors (2 sets) $2,000 (about $1,000 each)

Plexiglas (for VR Chemical Hood and VR bins – includes duplicates of bins)

$400

Machine Shop- stainless steel plate $220

Total $3761

Note: Terumo will use their own Machine Shop to manufacture the jig and VR Chemical Hood. Team will use UD Machine Shop to manufacture bins.

Revenue Analysis

• 15 additional units/hour• 30,960 additional units/year• $12,384,000 additional revenue/year• $1,145,520 additional material cost/year

• $11,238,480 net gain/year

Project Summary

• Lean manufacturing techniques such as VSM used to increase efficiency of manufacturing process

• Improved ergonomics for operators• Maximized space used• Decreased cycle time• $11.2 million net gain/year

Questions?