1. Design Optimization for
Dadant Product Work Cells
Bridgeway | Group #2
Students: Arielle Anderson-Venerable
Jordan Palmer
Kelsey Schreiber
Advisor: Prof. Sewoong Oh
Contact: Tammy Diefendorf
Scott Teel
Brittany Aten
1
3. “Creating Solutions for Everyone.”
Affirmative Employment Service
Physical and/or mental disabilities
Consumer vs. Productionist
Contract Work
Dadant & Sons -- Beekeeping Supplies
3
11. Problem Statement
Improve efficiency of facility layout
Reduce non-value added work & work in process
Decrease drying time for painted/primed hive bodies
11
12. 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
13. Paint Drying - Current State
13
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.
14. Paint Drying - Environmental Improvements
Move drying into paint room
Temperature Control
Dehumidifier
Air Ventilation
14
[Ivation 2016, Vornado 2016]
17. SLP- Flow Planner Initial Analysis
17
● Product/Part Routes Mapped in AutoCad
● Routes along Aisles
● Wage and Walking Speed along paths
● Aggregate per Monthly production
22. Balance workload among workstations
Decrease Idle Time
Decrease work pile-ups
22
Line Balancing- Introduction
23. 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
24. Line Balancing- Typical Method
24
● A new unit enters next workstation every 15 minutes
● Number of tasks/worker varies
25. Line Balancing- Alternative Approach
25
● A new unit enters the next workstation every 5 minutes
● Number of workers/task varies
29. Economic Analysis- Supply Increase
97 bodies per day → 2143/month
Current average: 1664/month
Revenue increase: $2,933.00
Total increase: $5,526.00
54% increase in average hive body
revenue
29
30. Conclusions
Loss of profit each month due to
layout
Hive body drying process is long
Bridgeway's supply from Dadant is
inconsistent
30
39. 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
44. “Creating Solutions for
Everyone.”
Est. 1993
Affirmative Employment Service
Physical and/or mental disabilities
9000 people employed/served per year
Contract Work
44
53. 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]
Editor's Notes
Kelsey (1-10)
Kelsey
Kelsey
Dadant & Sons
4-piece Box
4-piece Frame
10 per box
Plasticell inserts
~100 boxes per day
Consumers
Per-piece rate
Trainers
Productionists
Hourly
All jobs involving:
Movement
Painting
Machinery
Kelsey
Kelsey
Kelsey
Kelsey
Kelsey
Kelsey
Kelsey
Kelsey
Meaningful employment + exemplary products...
a. Optimize the facility layout to increase throughput and decrease productionist man-hours spent on material handling while accounting for the influx of temporary jobs and the space needed to accommodate them.
b. Integrate seconds frame production into new schematic.
c. Reduce non-value added work and work in process.
d. Decrease drying time of primed and painted boxes by investigating solutions to
increase air flow.
Kelsey
Conduct time studies. An understanding of the length of time that it takes for one beehive box to be constructed from start to finish is necessary in order to track overall metrics (man-hours/piece) from the start and end of the project.
Analyze the probability of frame reworking and seconds frames. To add robustness to the time studies it is important to account for the probability that a frame needs to be reworked or is damaged during the stapling process.
Use Systematic Layout Planning Method (SLP) to determine optimal layout. The project team will utilize a software add on to AutoCad called FlowPlanner which simulates the distance of product travel from start to finish. Adjustments to the layout can be made and distances recalculated until an optimal layout is determined.
Research options to increase air flow. The project team will investigate options to decrease drying time for the primed and painted boxes, which is currently highly variable depending on humidity, temperature, and air flow.
Recommend improvements in accordance with ISO standards. A set of recommended improvements will be compiled that satisfies the technical (layout and inventory efficiency) and social (employ the most consumers/increase workload) goals of Bridgeway. All recommendations should complement Bridgeway's goal of becoming certified by the International Standards Organization (ISO).
Jordan
Loss of profit each month due to improper work cell placement.
Hive body drying process must be shortened.
Bridgeway's irregular resupply timing and quantities are dragging down the Dadant project's contribution margin.
