1. Optimization of ATV Erector Set
Thomas Malloy
April Bouquard
Abdulrahman Mohammed Nuhuli
Leonard Arambam

2. Agenda
● Time Standards
● Line Balancing
● Workstation Analysis
● Ergonomics
● Part Presentation
● Iterations
● 5S implementation
● Conclusion

3. Time Study
Part 1:
● Members worked alone on constructing entire ATV.
● Identified steps to be timed (Battery, 1-24)
● Timed each step in seconds
Part 2:
● Users’ times were averaged together to identify
standard assembly times.
Phase Time (hrs)
Average 2.53
Final 1.16

4. Line Balancing
Goal: We want all workers to have the same
amount of time spent working.
● Precedence constraints did not allow for
optimal usage of Largest Candidate Rule
○ Grouped steps were very restrictive
● Divided steps into 8 blocks to be divided
between 4 workers.
○ 4 Long blocks and 4 short blocks
Worker # Time (sec)
1 2207
2 1973
3 2217
4 2710

5. Line Balancing (cont.)
● We reallocated steps from longer times to shorter times, but as the assembly
progressed we could not have all workers actively working on the same
product.
● Idle times between blocks allowed for flexibility.
○ Workers could help others when they lagged behind

6. Workstation Analysis
● Due to kitting and task analysis, workers
needed to be close together.
● Ordered 360 Degree Rotational Vices for
each workstation.
● Separated black screws and ¼” nuts into
separate containers.
● Kept tools in order
● Materials lay flat on the workstation (nothing
above the head)
● No foreign objects permitted

7. Workstation Analysis (cont.)
● Seated work aided in fine assembly and
allowed for necessary communication
● All materials were within 24 inches of the
worker
● Most used materials were within 14 inches
● Adjustable chairs with wheels provide
ergonomic benefits for workers of all heights as
well as ability to move laterally along
workstation
● Elevated tables for larger workers

8. Workstation Design Benefits
● Promotes a social atmosphere.
● Task order automatically designates idle times for workers
● Allows for quick passing of assembly
● Provides help from idle workers

9. Tooling
● Magnetized Allen Wrench
● Standard C-Frame Wrench (stock with set)
● 360 Degree Rotational Vice
● Spring Clips
● Power tools were bulky and too powerful
○ Stripped screws/nuts
○ Caused hand cramps/aches
● Hand tools allowed for precision and accuracy

10. Part Presentation
● Kitted parts rather than binning
○ Reduced time spent searching for parts.
○ Logical order to the steps
● All parts for worker job were within reach
● Kits had picture instructions as well as
what to do when a set of steps was
finished.

11. 5S Implementation
● Sort: Separate the unnecessary from the necessary parts
● Shine: Place for every part - labelling
● Set to order: Clean the workplace before manufacturing start of shift
● Standardize: SOPs
● Sustain : implement and execute

12. Ergonomic Evaluation Methods
● ACGIH TLV for Hand Activity
● Lighting Conditions
● Posture and repetitive work
● Mechanical Safety
● Job rotation.

13. ACGIH TLV Evaluation
Purpose: To asses the risk of hand injury in performing physically continuous
demanding jobs
Methods: Conducting ACGIH TLV for Hand Activity by accurately observing the
steps through videotaping
Results: Our results indicated that most of the work done by our right hand
needed some modification.

15. Implemented Improvements
● Ordered two 360 degree rotational vices to reduce TLV scores
● Magnetic Allen wrenches reduce overall movement during tightening the
screws and decreased the number of lost screws due to dropping
● Holding the assembly in with the vice reduced the strain on the dominant
hand while increasing nondominant hand usage

16. Lighting Conditions
OSHA Recommended:
● Illumination needed: >1500-2000 lux(lumen/m^2)
● Installation of overhead florescent lamp in the workstation with > 40 watt
● Incandescent lamp in the room with > 20 watt

17. Posture and Repetitive Work
● Total work per day: 8 hours with one hour lunch
● System capability: 16 ATVs
● Height adjustable chairs
● Elevated tables for comfortable leg room

18. Job Rotation
● Eliminate monotonous jobs and potentially harmful posture
● Cross functional training leads to a fully flexible workforce
● Isolate worker strengths
● Increase satisfaction and decrease muscle weakening rate
● Motivate employees to deal with new challenges

19. Iteration #1: Assembly Line/Binning
● Assembly line with binning at each station
● No change in step order
● Precedence constraints were severe
● No drastic change in time from single worker method

20. Iteration #2: Binning/Current Workstation Layout
● Allowed workers to work simultaneously
● Confusion during part selection
● Increased work time/lack of idle time
● Implemented magnetic c-wrenches and allen wrenches

21. Iteration #3: Kitting/Current Workstation Layout
● Easy part selection
● Low precedence constraint effect
● Workers had idle time to reorganize workstations
● Provided quickest assembly time
● Removed magnetized c-wrench tool after it was found to be ineffective

22. Quality Assurance
● Worker checklist to ensure
all steps are performed
● Signoff sheet to link worker
with steps performed as
well as determine routings
● Standard Operating
Procedures were developed
to standardize the way
steps were performed.

23. Workstation Recommendations
● Drawers or overhead hangers for tool storage
● Lightweight automated tools calibrated to output a set pressure/rotation
● Flow racks to allow for kits to roll towards and away from worker
● Cross training workers to better utilize skills

24. Idle Time
● Work on wheel assemblies or other small tasks
● Organize workstations
● Restock materials
● Help other workers
● Perform quality checks
● Start on a new kit

25. Conclusions
● Average Takt Time of 29 min
● Layout provided a “team” mentality
● Kitting reduced time spent searching for parts
● Magnetized tooling aided in assembly process
● 360 Degree Rotational vice freed non-dominant hand
● Cross training workers allows for flexibility and cost efficiency