Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation Report

Air Intake & Valve Cover Subassembly Line Improvement
Team # 28
Team Member Names
Avishek Ray, David Chen, Hao Ma, Mani Kumar, Joseph Zakhary
Faculty Mentor: Dr. Shimon Y. Nof
TA Mentor: Maithilee Motlag
Submitted to
Instructional Staff of IE 43100
And
Jason Hale, Engineering Manager,
Telamon Industrial Solutions, Carmel, Indiana
Final Report
In Partial Fulfillment of the Requirements for
IE 43100 - Industrial Engineering Design
Purdue University
School of Industrial Engineering
West Lafayette, IN 47906
Date of Submission
12/8/2019

Telamon: Air Intake and Valve Cover Subassembly Lines Improvement..................................Final Report
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Executive summary
The project objective is to reduce the probability of overtime for the air intake and valve cover
subassembly lines at Telamon Industrial Solutions facility in Carmel, Indiana. The team found a various
opportunity of improvement in the workstations based on observation, interviews, time studies, MTM
analysis as well as ergonomics analysis techniques. In this report, we propose the following solutions to the
problems encountered:
Problems Solutions
The traveling distance to the post-assembly product pallet is
increasing as a pallet level is filled.
Rotating pallet carousel
The per-pallet level quality check (QC) process is manual. QC using machine vision
Traffic congestion on the walkway leading to the production
cells and scope for Industrial 4.0 production communication
implementations
1. Remotely controlled bingo
board
2. Andon Studio Software
Unergonomic motions during production process Optimized Gasket tray holder
The graphics-only visual aids have limited capabilities Create written FAQs in English,
French, Spanish, German, and Chinese.
The cost estimates are as follows:
Solution Price estimate (USD)
Pallet rotating carousel * 8 $ 959 ∗ 8 = $ 7,672
Machine vision cameras * 8
($ 2,999 ∗ 8 = $ 23,992) + (𝐴𝑛𝑛𝑢𝑎𝑙: $ 350 ∗ 8 = $ 2,800)
= $26,792
Bingo board *1 + remote
switchboxes * 8
$ 5,800 + 8 ∗ $ 775 = $ 12,000
40-user Andon Studio license 40 user licenses + communication package = $ 46,549

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We recommend using machine vision in the post-assembly QC and Andon Studio for production
floor coordination. Implementing Andon Studio can be a significant step towards realizing the Factory of
the Future for Telamon Industrial Solutions.
Table of Contents
Executive summary ..................................................................................................................................... 1
Introduction and problem statement ............................................................................................................ 4
Current system model.................................................................................................................................. 5
Solution Approach....................................................................................................................................... 6
Methodologies ............................................................................................................................................. 7
Pain points mentioned by the client .............................................................................................................. 8
Proposed solutions....................................................................................................................................... 9
Approach 1: Optimizing assembly operations .............................................................................................. 9
Compartmentalize trays for screws and gaskets .................................................................................. 9
Install one rotating pallet carousel below each post-assembly pallet................................................. 11
Install a remotely controlled bingo board at warehouse and remote switch box at each station........ 11
Implement Andon Studio, a production floor information system..................................................... 12
Machine vision technology to improve QC ....................................................................................... 14
Approach 2: Training improvements .......................................................................................................... 16
Results ....................................................................................................................................................... 17
Approach 1:................................................................................................................................................. 17
Approach 2:................................................................................................................................................. 18
Discussion.................................................................................................................................................. 19
Approach 1.................................................................................................................................................. 19
Concerns about the installation of the rotating pallet carousel........................................................... 19
Concerns about installing the production floor information systems................................................. 19
Concerns about installing machine vision technologies..................................................................... 20
References ................................................................................................................................................. 21
Appendix ................................................................................................................................................... 22
Figures......................................................................................................................................................... 22
Calculations................................................................................................................................................. 34
Product URL ............................................................................................................................................... 35
Cell 2000 – MTM-UAS - Female worker (Valve Cover)........................................................................... 37

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Original MTM-1 Analysis (Valve Cover): Single Operator....................................................................... 38
Improved MTM-1 Analysis (Valve Cover): Single Operator.................................................................... 44
Original MTM-1 Analysis (Valve Cover): Dual Operators........................................................................ 51
Improved MTM-1 Analysis (Valve Cover): Dual Operators .................................................................... 58
Original MTM-1 Analysis (Air Intake)....................................................................................................... 65
Improved MTM-1 Analysis (Air Intake) ................................................................................................... 70
Gantt Chart.................................................................................................................................................. 74
Team member resumes................................................................................................................................ 75
Accounting of hours worked on the project to-date.................................................................................... 80

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Introduction and problem statement
As one of the largest private companies in Indiana, with eleven domestic and four international
locations, Telamon Industrial Solutions focus on simplifying business by increasing efficiency and
streamlining operations for its customers. They specialize in solutions for telecommunication networks,
industrial assembly, and business process outsourcing. Telamon is also committed to the local communities
of their employee base. At Carmel, Telamon assembles subassemblies for customers such as Cummins and
John Deere. The assembly tasks are performed by contract workers trained to run specific assembly cells.
The assembly lines at Telamon faces frequent over time. The product cycle time is not contributing
to the problem since an operator can easily assemble a unit within five minutes. Instead, factors such as
large per-order quantities, sub-optimal workstation setup, lack of automation, and inefficient cooperation
often led to overtime work. Furthermore, the team observed that overtime workers often do not follow
standardized assembly procedures but how it is convenient for them. The high worker turnover rate further
exacerbates the problem.
Our solution offers improvements in workstation design, operational practice, and training. The
proposal also introduces new technologies to the production floor for two different budgetary situations.
The Air Intake and Valve Cover subassembly lines need to reduce overtime probability to
overcome the challenge from large order quantity. The formal problem statement is to “optimize and
standardize operations for the Air Intake and Valve Cover Subassembly lines at Telamon Industrial
Solutions to increase productivity by about 10-15%.”

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Current system model
Figure 1: System model
Telamon only contributes assembly force to Cummins. The company receives product components
from Cummins’ suppliers at predetermined prices. Cummins had negotiated the component costs with its
Cell 2000
Stop after filling
every pallet level
Supplies
Parts to
Air
Intake
Valve
Cover
Rejected
Parts
Rejected
Parts
Must
inspect
before
proceeding
Must inspect
before proceeding
Must inspect
before
proceeding
Defective
Parts
Cummins
Has price
authority
over
Quality
Defective
Parts
Telamon Warehouse
@ Carmel, IN
QC per pallet level
by traveling
Inspector (Kim)
Parts Suppliers
Cell 2700
Stop after filling
every pallet level
Cell 2600
Stop after filling
every pallet level
QC per pallet level
by traveling
Inspector (David)

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suppliers, who will send the parts to Telamon. According to Jason, the operations manager, the suppliers
were told to treat Telamon as if it is part of Cummins. Telamon provides assembly service to Cummins and
accepts contract logistics to receive and return components to the suppliers.
The improvement proposal focuses on the Air Intake (Figure 9, Figure 10) & Valve Cover (Figure
12) subassembly line inside the Telamon Industrial Solutions facility in Carmel, Indiana (Figure 7, Figure
8: CAD layouts). The production floor has around 80 operators, five of which are workers on the production
in the project scope. The Air Intake line consists of cells 2700 and 2600, and the valve cover line only has
Cell 2000.
Solution Approach
Figure 2: Solution approach model

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Methodologies
The team visited Telamon almost once a week for the first 6 ~ 7 weeks of the project timeline to
understand in-depth about the client’s current system. The team took pictures and videos to understand and
analyze areas to improve and reduce overtime. Methods used by the team were
• MTM Analysis and Time Studies (Complete analysis can be found in the Appendix)
• CATIA reach envelope analysis
• Operator Interviews
Upon going over the findings of the teams analysis, it was clear that the overtime probability could be
reduced by improving the workstations and some assembly motions as well. A few pain points noticed by
the team were:
1. The current practice of relocating the empty bins behind the full ones is unergonomic due to a
significant increase in reach distance. The containers are nearly one square foot in size. The practice
also disrupts the Kanban rack's incoming material flow.
2. The gaskets used in the Air Intake subassembly are placed on vertical poles of the Kanban rack.
Each pole holds ten to fifteen gaskets. The operator’s travel distance for the gaskets increases as
the closest gasket stack is consumed first. (Figure 10, Figure 14, Figure 15).
3. The Air Intake & Valve subassembly consists of metal casts and can weigh as much as 12 pounds.
The operators need to handle the subassembly around 120 times daily (
89 :;
<=>
∗
?9 @AB
:;
∗
8 C>CDE
F @AB
=
120
C>CDEG
<=>
, assuming the cycle time is 5 minutes). Since the unit is heavy and the operators are not
observed to wear steel-toe shoes, dropping the subassembly during transfer can lead to serious
injury. It is also strenuous to travel while carrying these heavy parts to empty pockets on the pallet
beyond the operator’s reach.

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4. The current production floor communication method is inefficient. The logistics crews were seen
to check the raw material supply at each manufacturing cell personally. Such practice is
unproductive, wastes operator energy, and increases the production floor traffic. Therefore,
production information technology is needed to communicate supply consumption and coordinate
different teams on the production floor.
5. The team also observed a 15-minute halt in valve cover production due to the QC worker’s delayed
arrival. According to the product’s assemblers, the situation happens quite often due to having two
QC workers covering eight locations. The wait time varies greatly, from minutes to tens of minutes,
depending on the QC worker’s workload. Since every pallet layer must be checked before a new
layer can be filled, the inspection mechanism is the most critical component in the system. Its
performance greatly influences daily output.
Pain points mentioned by the client
During our visits to Telamon, the client stated that operators do not always follow the instructions
while assembling the products. The information led the team to take an in-depth look at the operator training
process. The current training consists of shadowing an existing operator and reading visual aids. Since
Telamon has a linguistically diverse workforce (seven languages), the visual aids are graphics-only. The
design limits the visual aid’s information capacity and clarity.
There should be written FAQs for the visual aids to explain details that are impossible to capture
by pictures alone. If everything can be expressed in terms of graphics, there won’t be so many languages
in the world. According to US Census on languages in Indiana 2009-2013, 45.7 % of the population speaks
English and only 1.5 % of the population speaks English ‘less than very well’. The top languages are, in
descending order of speaker population: English (6,087,409), Spanish (277,381), German (35,409), Chinese
(23,119), and French (13,770) (United States Census Bureau, 2019). Production floor recruits should be
surveyed anonymously about the visual aid’s clarity after comparing it with an operator shadowing

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experience. The feedback will help Telamon writing the FAQs to clarify the variability in interpreting the
graphics.
Proposed solutions
Approach 1: Optimizing assembly operations
The team treated each problem individually and worked on coming up with the most efficient and
practical solutions. In order of the issues stated earlier, the team's solutions are:
Compartmentalize trays for screws and gaskets
The current screws tray of the Air Intake assembly line (green circle in Figure 10) should be split
into two sections to store the gaskets and screws separately. The change will increase the gasket holding
capacities and combine all gasket supplies into one location. The current practice of having multiple gasket
stacks across significant distances creates unnecessary travel distances (red circle in Figure 10, Figure 14,
Figure 15).
Figure 4: Example of a compartmentalized tray for Air Intake
Hex Flange Head Cap
Screw, Part No. 3937434
Connection Gasket,
Part No. 4933235

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Pre-tightening of bolts
Using screwdrivers to pre-fasten the screws is unnecessary. According to MTM-1 card (Lehto &
Landry, 2013) and the MTM-1 analysis performed on Cell 2700(MTM-1 analysis of the Air Intake in
Appendix), the total time related to the use of a screwdriver is 4.61 seconds (Improved MTM-1 analysis of
Air Intake in Appendix), which is 4.6% of assembly time. However, after observing the operation of Cell
2000’s Breather section, the team devised that the pre-tightening of screws/bolts can be finished by hand
instead.
Gluing location and clockwise
The operator should apply the chemical to the valve cover's gasket groove, either clock or
counterclockwise. The current visual aid suggests the operator start from the upper left corner, which is 30
inches from the solution container. According to the MTM-1 data card and our MTM-1 analysis of the
assembly process, starting from the right-hand side will save 38 TMUs or 1.4 seconds. In general, the
operator's fatigue rate is proportional to the distance between the initial brush placement and the body
(Lehto & Landry, 2013).
Pasting barcode
The operator should paste necessary barcodes onto the product while the gasket is being installed
automatically. The automatic gasket installation takes 334 TMUs according to our MTM-1 analysis.
Installing the air cap and barcode takes 137 and 49 TMUs, respectively. Since the TMU sum of these two
tasks remains well below 334 and the supplies are within reach, the operator should complete these tasks
during the automatic gasket installation.
Marker location
The marker should be placed in the middle between gasket module and desktop of gasket
workstation. Based on Valve Cover MTM-1 Analysis and video record, catching marker from right side
consumes 32 TMUs more, which is 1.2 seconds. Besides, right-hand location of marker requires more

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TMUs in that the marker is out of direct vision range, which asks operator move body or extra selecting
action. Thus, with original location of marker, the operator takes more than 1.2 seconds in real practice.
Install one rotating pallet carousel below each post-assembly pallet
A rotating pallet carousel, as seen in Figure 5, should be installed to mitigate the current risky and
inefficient way of filling the post-assembly product pallet. Currently, the post-assembly pallets are
stationary. The operator’s walking distance increases as a pallet layer is being filled. The growing travel
distance leads to an increase in completion time per pallet layer.
A rotating pallet would reduce the walking distance by bringing the empty cells on a pallet layer
closer to the operator. The travel distance will be constant and minimized. The minimized walking distance
also reduces the probability of foot injury, since the workers aren’t wearing steel-toed shoes, and the
products are large and of considerable weight (around 10 lbs.).
Figure 5: Rotating Pallet Carousel
Install a remotely controlled bingo board at warehouse and remote switch box at each station
The team proposes the installation of a remote-controlled bingo board and eight remote switch
boxes to report each manufacturing cell’s supply situation to the logistics service as a less disruptive
solution. The recommended vendor is SignalWorks in Ohio. The board would be installed at the logistics
crews' traffic hotspot to maximize visibility. The color being lit indicates the remaining supply level: green
for 100 ~ 66%, amber for 66 ~ 33%, and red for 33 ~ 0%. The blue light can be used to signal for post-
assembly product pallet removal. The remote will be secured in place near the supplies for ease of access.
After receiving fresh supplies, the operator needs to reset the signal to green to start the cycle anew. The

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signaling rules will be added to the training material. There will also be reminders next to the remote. The
powerful remote has an effective signal range of 2000 feet, capable of reaching anywhere in the facility.
Able to switch among eight frequencies and uses the 900 MHz wireless communication protocol, the remote
connection is also secure and robust. Lastly, SignalWorks can sell to the described product to Telamon for
12,000 USD plus shipping from Ohio.
The benefits of implementing the signaling system include reduced traffic, stamina conservation,
and improved work experience. The bingo board will keep the logistics crew informed about the supply
level in real-time without having to check the levels manually. The system can significantly reduce the
logistics crew’s travel frequency. Avoiding only five unproductive travels every day can recover 51 hours
of productive time for the logistics crew (Calculation 3, assuming 646 feet per logistics run on average).
Having to travel less also conserves worker stamina and improve the work experience. The saved time can
be used to rest or for tasks such as supply preparation.
Implement Andon Studio, a production floor information system
Andon Studio by Famic Technologies is an integrated software that specializes in real-time
production monitoring and control. The software is available on both PC and mobile platforms, allowing
the construction of an integrated communications network within the production system. The mobile app
gives workers the ability to respond to requests while the PC version can send requests and view all
performance indicators. The software can also follow a pre-determined organizational architecture to
escalate the issue to higher management. Andon Studio also improves the traceability of errors when
working with scanners and sensors.
Employing Andon Studio can bring Telamon closer towards realizing the Factory of the Future.
The software can help connect all members of the production line as well as to other facilities and the
suppliers. Externally, the free flow of information will improve responsiveness for all members of the
network. Internally, the software will help coordinate different production teams and maintenance efforts.
Andon Studio can keep the management informed about the production situation as well. The software can

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communicate across all levels of the production organization. We believe Andon Studio will help Telamon
in becoming Factory of the Future by integrating isolated information silos into a seamless, fully integrated
system of systems.
Based on the communication with the company, the main server minimal requirements and
recommended requirements are described in Table 1. From the CPU Benchmarking site on the table, AMD
Ryzen 9 3900X is the most reasonably priced among the top 6 CPUs, at $564.44. The RAM required will
cost no more than $200. For example, DDR4 RAM at Best Buy (Memory (Ram) n.d.) can be as low as $58
for 16 GB. For the hard drive, Amazon has SSD Samsung 850 PRO for $281.40 at the time of writing. A
license for Windows Server 2016 can be around $700, which is lower than the most recent 2019 version,
which starts at $972. SQL Server 2017 pricing depends on the processing power used instead of the cores
in the system, but it can be as low as $931. Lastly, the motherboard used can be as low as $182, the ASUS
ROG Strix X470-F. The cost estimate for the entire server setup is $2,858.84.
Computer
Type
Requirement Minimal Recommended Cost
Main
Server
v 3.5.1
CPU
Rating higher than 9 in this
benchmark:
https://www.cpubenchmark.net/h
igh_end_cpus.html
Higher performance $564.44
RAM 16 Gb 32 Gb $200
Hard drive 256 Gb SSD + RAID $281.40
OS Windows Server 2012 R2
Windows Server
2016
$700
Database SQL Server Express 2012
SQL Server 2017
Enterprise Edition
$931
Interfaces
(Motherboard)
For a USB hardware license key and when the server is a
virtual machine, this module is required:
https://www.digi.com/products/models/aw-usb-2
$182
Table 1

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Machine vision technology to improve QC
Machine Vision inspection devices combine photography and technologies such as feature
recognition to perform vision-based tasks for humans, who are proven to be prone to mistakes. Using
Machine Vision can drastically save time in the production process and reduce the labor required.
Equipment used in creating a machine vision solution will vary based on the type of application,
the environmental conditions, and quality control standards. Knowing the best combinations of equipment
and how to integrate them into the manufacturing process is crucial to the success of any machine vision
project.
Comparison of CMOS and CCD cameras – (howstuffworks.com, 2019)
Complementary Metal–Oxide–Semiconductor
(CMOS)
Charge-Coupled Device (CCD)
CCD sensors create high-quality, low-noise images. CMOS sensors, traditionally, are more
susceptible to noise.
Because each pixel on a CMOS sensor has several
transistors located next to it, the light sensitivity of a
CMOS chip tends to be lower. Many of the photons
hitting the chip hit the transistors instead of the
photodiode.
CCD sensors have been mass-produced for
a longer time, so they are more mature.
They tend to have higher quality and more
pixels.
CMOS traditionally consumes little power.
Implementing a sensor in CMOS yields a low-power
sensor.
CCDs use a process that consumes lots of
power. CCDs consume as much as 100
times more electricity than an equivalent
CMOS sensor.

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CMOS chips can be fabricated on just about any
standard silicon production line, so they tend to be
extremely inexpensive.
CCD sensors are generally on the expensive
side.
Visual inspection automation
Table 2 contains all the QC requirements extracted from Telamon's existing QC documentation and
explains how they are covered by a combination of machine QC and existing checks. Using Machine vision
systems in manufacturing and production environments allows for increased QC and production efficiency.
QC can be achieved by using smart cameras and machine vision technology to carry out repetitive visual
inspections accurately. Based on the QC process at Telamon, the team has formulated all the requirements
needed to be detected by the machine vision system (Table 2).
Table 2: Requirement Analysis
The team also researched and found two systems that could be installed and used to meet these
requirements and did a comparative analysis of both the systems in Table 3. Based on the research, the VS2
Samsara camera system seemed to be most applicable for Telamons needs. The went ahead and contacted
the company to get a price quote and also discuss feasibility and effectiveness of installing the system. The
key difference between the two systems was in maintenance and communication. With Samsara being

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relatively newer than Cognex and specializing in such a niche business need, its responsiveness to
maintenance issues are extremely good and that is something Telamon should definitely value considering
the fact that if the machine vision system were to break or fail at any point, they will have a quick repair
option with Samsara. They are also the cheaper solution.
Features Samsara VS2 Cognex Insight Vision 8000
Price $26,792 $30,600
Relevant Industrial Case histories ✔ ✔
QC Vision technology ★★★★ ★★★
Ease of installation ★★★★★ ★★★
Maintenance and communication ★★★★★ ★★
User Friendly Interface ★★★★ ★★★★
Table 3: Comparative Analysis for Machine Vision Cameras
Approach 2: Training improvements
The company should strive to keep its workforce motivated by cross-training them among different
manufacturing cells. Even though the current subassembly process is short and easy to complete, chronic
repetition of the same tasks can lead to boredom, morale loss, and eventual resignation. Losing long-time
workers is one of the significant factors contributing to the loss of productivity, and cross-training can
reduce that.
The training instruction should address motion paths and time arrangements to improve clarity and
overall efficiency. Motions such as brush and roller use are not indicated in the visual aids (Figure 22).
Having these descriptions added will reduce the need to shadow the current operator, thus reducing training
time.

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9%
31%
16%
44%
PERCENTAGE COST SAVED BY
EACH SOLUTION IN A YEAR
Results
By going through our approach and implementing our proposed improvements, the team would
expect to see a significant change in the efficiency of both the Air Intake and Valve Cover assembly lines.
The multiple ergonomic improvements suggested to the assembly lines would help in reducing operator
fatigue, decrease excess overtime, and increase the production efficiency of the lines.
Approach 1:
Solution Time savings
Percentage reduction in
production time
Rotating pallet carousels 33mins/200parts 7.66%
Andon studio software and
Bingo board
3mins/200parts 0.68%
Optimized Gasket tray holder
and other ergonomic assembly
improvements
17mins/200parts 3.91%
Machine Vision QC 17mins/200parts 3.91%
Table 4: Time savings per proposed solution
24%
48%
4%
24%
PERCENTAGE TIME SAVED BY EACH
SOLUTION PER WORKSTATION
Optimized tray design
Rotating Carousel
Production Floor Info System
Machine Vision System

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Figure 6: Times savings after improved processes
Approach 2:
The suggestion of cross training the operators would help tackle the frequent operator’s turnover
more efficiently. It would not only lead to a more dynamic work style but also give Telamon the flexibility
of moving around operators to the most efficient production combination. Having the learning experience
and the opportunity to do different things enhances psychological resources, such as hope, optimism, and
resilience of the worker, all of which are important to mental health (Wang, et al., 2017). Cross training the
workers diversify their experience and increase their utility for the company at a low cost.
Having the opportunity to do different things enhances human psychological resources, such as
motivation and self-esteem, all of which are important to workers’ long-term performance and job
satisfaction. Cross training the workers will diversify their experience and increase their utility for the
company.
0
50
100
150
200
250
300
350
400
450
500
Current Production Time Improved Production Time
Overall Time Savings
Reduced production time
by an overall 16.09%

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Discussion
Approach 1
Concerns about the installation of the rotating pallet carousel
Safety
Installation of the rotating pallet carousels needs approval from production-related departments.
These devices will become fixtures on the production floor, which will require approval from departments
such as safety before being implemented. The method of implementation of the carousels is also a
contentious issue. The above-ground approach can be a tripping hazard, while the underground method
requires significant modification of the facility's floor. Additionally, they are not cheap since one can cost
nearly a thousand dollars. The team needs to perform a cost-benefit analysis to back up the proposal.
Opposition on necessity grounds
Since the rotating pallet carousels are fixtures, acquiring them would be a significant monetary
investment and subject of concern for both Telamon and its clients. The decision-making process may
involve Cummins in the scope of this project.
Concerns about installing the production floor information systems
Additional server investment
Implementing Andon Studio might lead to a server investment of around $3000. Nevertheless, the
software does not require a dedicated server.
Fragile monitoring devices
There is a safety concern in using tablets or iPads on the work floor since the assembly process is
quite physical. There is a possibility of damaging these devices, which will incur replacement costs.

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Additional training required
Since the addition of the production floor system will be a new addition to the operators and
appropriate workers, training in how to use, either the Andon Studio system or Bingo Boards, would be
required. Workers need to understand how to operate the hardware devices.
Concerns about installing machine vision technologies
Proper placement and detection of QC
The installation and placement of the camera are most vital for it to be able to detect the required
seamlessly quality checks. Samsara is an industry leader in camera vision technology, and they have had
quite a few cases of implementing machine vision to replace manual QC however, both firms will need to
cooperate with each other regarding installation and operation to achieve the best results.

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Appendix
Figures
Figure 7: CAD layout of subassembly lines.
Cell 1: Valve Cover subassembly
Cells 6, 7, 8: Air Intake subassemblies

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Figure 8: CAD layout of Telamon Warehouse

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Figure 9: Air Intake subassembly line (Panorama)
Figure 10: Air Intake subassembly line (Top view)

P a g e 25 | 91
Figure 11: Air Intake workstation inputs and issues found
Figure 12: Valve cover subassembly line
DNF pressure
sensors ~21
Air-fuel throttle
valves ~15
Air Intake
Connections ~4
Poorly sloped/lubricated
rollers

P a g e 26 | 91
Figure 13: Valve Cover subassembly line (Top view)
Figure 14: Gaskets on a vertical pole extension of the workstation
Gaskets

P a g e 27 | 91
Figure 15: Gaskets on vertical pole extensions of the workstation
Figure 16: Example of a defective-parts container
Gaskets

P a g e 28 | 91
Figure 17: Picture of newly arrived metal casts in trays

P a g e 29 | 91
Figure 18: Layout of the valve cover assembly cell

P a g e 30 | 91
Figure 20: The sum of the distances in the red boxes is 323 feet.

P a g e 31 | 91
Figure 21(1): CATIA Air Intake workstation layout with maximal physiological reach envelope
Figure 21(2): CATIA Improved Air Intake workstation layout with maximal physiological reach envelope

P a g e 32 | 91
Figure 21(3): CATIA Valve Cover workstation layout with maximal physiological reach envelope
Figure 21(4): CATIA Improved Valve Cover workstation layout with maximal physiological reach envelope

P a g e 33 | 91
Figure 22: The original v. new visual aid with motion path arrow
Table 5: Machine Vision System Comparison

P a g e 34 | 91
Calculations
Calculation 1:
Rotating Pallet Carousel Values Units
Time saved/part produced 10 secs
# of parts 200 parts
Daily time saved 2000 secs/day
Daily time saved 33 mins/day
Average Daily Operator working time 435 mins/day
% time saved per day 7.66% % saved/day
Calculation 2:
Optimized gasket tray and other ergonomic
assembly motion improvements
Values Units
# of steps taken saved per unit produced 5 steps
Time per step (assume) 1 sec
Average Daily Production 200 units
Daily time saved 16.67 mins/day
Calculation 3:
Production floor information system Values Units
Walking distance per lap 646 ft
# of laps saved per day (assume) 10 laps
Working days per year 261 days
Annual walking distance saved 1686060 ft
Average walking speed* 1.4 m/s
Average walking speed (converted) 16535.4 ft/hr
Time saved (hrs) 101.97 hrs/year
Daily time saved per work station 2.93 Mins/day
Assuming the new signaling system can reduce around ten manual check trips daily.
*The average walking speed of normal-weight adults is 1.4 m/s, which is used to calculate the annual hours
saved (Browning, Baker, Herron, & Kram, 2006).

P a g e 35 | 91
Calculation 4:
All the Andon lights are custom-built by SignalWorks from Ohio.
Eight switch boxes + 8 Andon lights (red, amber, green blue):
Total cost = 8*775 + 8*875 + shipping from Ohio = 13200 + shipping
Eight switch boxes + one bingo board (red, amber, green blue):
Total cost = 8*775 + 5800 + shipping from Ohio = 12000 + shipping
Calculation 5:
Machine Vision QC Values Units
Time saved/part produced 5 secs
# of parts 200 parts
Adapting the machine vision system saves an average of 60secs for the quality check of every 12
parts (the average between 6 valve covers and 16 air intake valves per pallet level)
Product URL
Pallet carousel:
https://www.globalindustrial.com/p/material-handling/lift-tables/pallet-carousels/best-value-pallet-
carousel-skid-turntable-4000-lb-cap-51-usable-
dia?infoParam.campaignId=T9F&gclid=EAIaIQobChMI_tq80_fT5QIVSpyzCh1jAgddEAkYASABEgLcW
vD_BwE
Andon light system:

P a g e 36 | 91
https://www.signaworks.com/products/wireless-led-Andon-light-and-system/handheld-wireless-Andon-
tower-light.html
The candidate server:
https://www.cyberpowerpc.com/page/AMD/Ryzen-3000/

P a g e 37 | 91
Cell 2000 – MTM-UAS - Female worker (Valve Cover)
Video Date: 9/20/2019
Video Name: Cell 2000 Female Worker
Description: Record of a female worker working on a valve cover
from start to finish
Comments: The automatic testing is partially recorded.
Action Time
(sec.)
Comment
Take a gasket from a bundle 5
Place the gasket along the groove 16 specify task requirement
Take brush from solution tray 3
Apply the solution on the valve cover 7
Return the brush 1
Transfer valve cover to station 1 5
Activate station 1 4
Install plastic cap 7
Activate station 1 4
Obtain, paste, scan and mark label 15 investigate label placement
alternative location
Transfer valve cover to station 2, engage
sensor
4
Use the roller on the gasket 11
obtain and apply oil to the screw holes 7 (get the plate at the same time)
Place the plate precisely 2
obtain and install screws using the torque
gun
22
disengage sensor, transfer valve cover to
station 3, engage sensor
10
obtain breather, the brush, and apply the
solution
8
install breather 5

P a g e 38 | 91
Original MTM-1 Analysis (Valve Cover): Single Operator
Valve Cover MTM Analysis (Operator 1)
Left Hand Right Hand
Symbol Action description TMUs(ide
al)
TMUs(ide
al)
Action description Symbol Operator
1 TMU
W_P3 walk to gasket 45 45 walk to gasket W_P3 45
R12A reach gasket 9.6 9.6 reach gasket R12A 9.6
G1A grasp gasket 2 2 grasp gasket G1A 2
M24A lift gasket up 22.4 22.4 lift gasket up M24A 22.4
W_PO
3
bring gasket to
workstation
51 51 bring gasket to
workstation
W_PO
3
51
P3SE position gasket into
pocket
445 445 position gasket into
pocket
P3SE 445
TBC1 turn body 18.6 18.6 turn body TBC1 18.6
W_P5 walk to valve cover 75 75 walk to valve cover W_P5 75
R24A reach valve cover
board
14.9 14.9 reach valve cover
board
R24A 14.9
M24A remove valve cover
board
22.4 22.4 remove valve cover
board
M24A 22.4
R24A reach valve cover 14.9 14.9 reach valve cover R24A 14.9
G1A pick up valve cover 2 2 pick up valve cover G1A 2
12.3 reach brush R18A 12.3
2 grasp brush G1A 2
27.1 move brush onto
edge of VC
M30A 27.1
obtain and pre-fastening the screws 19 investigate whether pre-fastening is
needed
use the screw gun to tighten the screws 32
obtain and place sensor frame, then return
it
6

P a g e 39 | 91
63.38 apply glue M68A 63.38
27.1 return brush M30A 27.1
W_P5 move to test station 75 75 move to test station W_P5 75
8.7 reach wire head R10A 8.7
2 grasp wire head G1A 2
11.3 remove wire M10A 11.3
R10A reach socket 8.7 8.7 reach socket R10A 8.7
G1A grasp socket 2 2 grasp socket G1A 2
APB release socket 16.2 16.2 release socket APB 16.2
handle
handle
R12A 9.6
G1A grasp valve cover
handle
2 2 grasp valve cover
handle
G1A 2
M12B lift valve cover up f
=1.17
15.678 15.678 lift valve cover up f
= 1.17
M12B 15.678

P a g e 40 | 91
W_PO
12
walk to pallet
w/VC
204 204 walk to pallet
w/VC
W_PO
12
204
M40C place valve cover
into pallet
64.7 64.7 place valve cover
into pallet
M40C 64.7
W_P10 walk to valve cover
casting
150 150 walk to valve cover
casting
W_P10 150
casting
casting
G1A 2
W_PO
4
walk with cover
casting
60 60 walk with cover
casting
W_PO
4
60
M16C move VC casting
onto WS f1.17
21.879 21.879 move VC casting
onto WS f1.17
M16C 21.879
waiting processes
w/cover plc
334 334 waiting processes
w/cover plc
334
R24A remove hand from
VC casting
14.9 14.9 remove hand from
VC casting
R24A 14.9
R24A reach VC casting 14.9 14.9 reach VC casting R24A 14.9
G1A grasp VC casting 2 2 grasp VC casting G1A 2
P3SD lift VC casting up 48.6 48.6 lift VC casting up P3SD 48.6
R20A reach barcode 13.1 13.1 reach barcode R20A 13.1
G4C grasp barcode 12.9 12.9 grasp barcode G4C 12.9
M20C move barcode onto
VC surface
22.1 22.1 move barcode onto
VC surface
M20C 22.1
P2SE paste barcode 16.2 16.2 paste barcode P2SE 16.2
14.9 reach marker R24A 14.9
2 grasp marker G1A 2
G1A grasp maker 2 22.4 pass marker to left
hand
M24A 22.4
M12B pass marker to right
hand
13.4 2 grasp marker G1A 13.4
10.6 take off maker cap M8B 10.6
16.2 write number APA 16.2

P a g e 41 | 91
11.8 tighten marker cap M8C 11.8
22.4 return marker M24A 22.4
12.9 reach scanner R12B 12.9
2 grasp scanner G1A 2
15.2 scan barcode 1 M12C 15.2
12.9 return scanner M12A 12.9
R14A reach VC casing 10.5 10.5 reach VC casting R14A 10.5
M12B lift up VC casting f
= 1.17
15.678 15.678 lift up VC casting f
=1.17
M12B 15.678
W_PO
2
walk to WS2 w/
VC casting
34 34 walk to WS2 w/
VC casting
W_PO
2
34
M12C place VC casting f
= 1.17
17.784 17.784 place VC casting
f=1.17
M12C 17.784
15.8 reach roller R16B 15.8
2 grasp roller G1A 2
15.8 Pick up roller M16B 15.8
R12B reach roller 12.9 12.9
G1A grasp left handle 2 2
M14A place roller on VC
top
10.5 10.5 place roller on VC
top
M14A 10.5
P3SE secure gasket 556 556 secure gasket P3SE 556
R12C reach VC casting
side
14.2 14.2 reach casting side R12C 14.2
M12C lift up VC casting
f=1.17
17.784 17.784 lift up VC casting
f=1.17
M12C 17.784
W_PO
3
walk to WS3 51 51 walk to WS3 W_PO
3
51
M14C place VC casting
on WS f=1.17
on WS f=1.17
M14C 19.773

P a g e 42 | 91
7.9 reach socket R8A 7.9
10.6 lock socket APA 10.6
SS_C1 1step left 17 17 1 step left SS_C1 17
R22A reach breather 14 14
G1A grasp breather 2 2
M26C pick up breather 27.3 27.3
2 grasp brush G1A 2
112 apply glue P2SE 112
9.6 hand back to
breather
R12A 9.6
M10A move breather to
location
11.3 11.3
P2SD install breather 26.6 26.6 install breather P2SD 26.6
11.4 reach bolts R16A 11.4
2 grasp bolt 1 G1A 2
14.4 pass bolt 1 to left
hand
M14A 14.4
M10C move bolt to thread 13.5 13.5 move bolt to thread M10C 13.5
T720S pre-fasten bolt 56.4 56.4 pre-fasten bolt T720S 56.4
R14A reach torque gun 10.5 10.5 reach torque gun R14A 10.5
G1A grasp torque gun 2 2 grasp torque gun G1A 2
M16C place torque gun to
bolt 1
18.7 18.7 place torque gun to
bolt 1
M16C 18.7
P2SE fix torque gun 16.2 16.2 fix torque gun P2SE 16.2
tighten bolt 83.3 83.3 tighten bolt 83.3
bolt 2
bolt 2
M6C 10.3

P a g e 43 | 91
16 return torque gun M16A 16
R20A reach breather 13.1 13.1 reach breather R20A 13.1
G1A grasp breather 2 2 grasp breather G1A 2
M12C lift up VC f=1.17 17.784 17.784 lift up VC f=1.17 M12C 17.784
W_PO
4
bring VC to WS4 68 68 bring VC to WS4 W_PO
4
68
M16C position VC f=1.17 21.879 21.879 position VC f =1.17 M16C 21.879
G1A grasp handle 2 2 grasp handle G1A 2
P3SD tighten socket 48.6 48.6 tighten socket P3SD 48.6
25.3 plug in wire P2SSD 25.3
7.9 reach inset R8A 7.9
2 grasp inset G1A 2
21.8 plug in inset P2SD 21.8
14 reach black button R22A 14
5.6 press black button P1SE 5.6

P a g e 44 | 91
22.9 scan QR code M26B 22.9
17.2 reach marker R18B 17.2
17.6 bring marker to QR
code
M18A 17.6
5.7 take off marker
head
D1D 5.7
16 mark P1NSE 16
10.6 tighten marker head APA 10.6
Total TMU 4371.419
Total Sec 157.3710
84
Improved MTM-1 Analysis (Valve Cover): Single Operator
Single Operator Valve Cover (Improved) MTM Analysis
Symbol Action description TMUs(ideal) TMUs(ideal) Action description Symbol Operator
TMU
W_PO3 bring gasket to
workstation
workstation
W_PO3 51
P3SE position gasket into
pocket
pocket
P3SE 445

P a g e 45 | 91
W_P5 walk to valve cover 75 75 walk to valve cover W_P5 75
board
board
R24A 14.9
M24A remove valve cover
board
22.4 22.4 remove valve
cover board
M24A 22.4
G1A pick up valve cover 2 2 pick up valve cover G1A 2
2 grasp brush G1A 2
8.1 move brush onto
edge of VC
M6A 8.1
W_P5 move to test station 75 75 move to test station W_P5 75

P a g e 46 | 91
handle
handle
R12A 9.6
handle
handle
G1A 2
M12B lift valve cover up f
=1.17
15.678 15.678 lift valve cover up
f = 1.17
M12B 15.678
W_PO4 walk to pallet w/VC 68 68 walk to pallet
w/VC
W_PO4 68
M40C place valve cover into
pallet
into pallet
M40C 64.7
TL90 rotate carousel 16.2 16.2 rotate carousel TL90 16.2
W_P4 walk to valve cover
casting
casting
W_P4 60
casting
casting
G1A 2
W_PO4 walk with cover
casting
casting
W_PO4 60
M16C move VC casting onto
WS f1.17
onto WS f1.17
M16C 21.879
waiting processes
w/cover, barcode
w/cover, barcode
334
R24A remove hand from VC
casting
VC casting
R24A 14.9

P a g e 47 | 91
G1A grasp maker 2 11.8 scan barcode 2 M8C 11.8
12.9 pass marker to left
hand
M12A 12.9
M12B pass marker to right
hand
13.4 return marker M12B 13.4
M12B lift VC casting f = 1.17 15.678 15.678 lift VC casting f
=1.17
M12B 15.678
W_PO2 walk to WS2 w/ VC
casting
VC casting
W_PO2 34
M12C place VC casting f =
1.17
f=1.17
M12C 17.784
M14A place roller on VC top 10.5 10.5 place roller on VC
top
M14A 10.5
R12C reach VC casting side 14.2 14.2 reach casting side R12C 14.2

P a g e 48 | 91
f=1.17
f=1.17
M12C 17.784
W_PO3 walk to WS3 51 51 walk to WS3 W_PO3 51
M14C place VC casting on
WS f=1.17
on WS f=1.17
M14C 19.773
2 grasp brush G1A 2
9.6 hand back to
breather
R12A 9.6
location
11.3 11.3
hand
M14A 14.4
M10C move bolt to thread 13.5 13.5 move bolt to thread M10C 13.5

P a g e 49 | 91
bolt 1
bolt 1
M16C 18.7
bolt 2
bolt 2
M6C 10.3
M12C lift VC f=1.17 17.784 17.784 lift VC f=1.17 M12C 17.784
W_PO4 bring VC to WS4 68 68 bring VC to WS4 W_PO4 68
M16C position VC f=1.17 21.879 21.879 position VC f
=1.17
M16C 21.879

P a g e 50 | 91
2 grasp inset G1A 2
code
M18A 17.6
5.7 take off marker
head
D1D 5.7
16 mark P1NSE 16
10.6 tighten marker
head
APA 10.6
Total TMU 4038.819
Total Seconds 145.397484
Note:
1. The process of pasting barcode is merged with auto-press gasket process. Because auto-press gluing
process has 18 seconds in the video record. The operator can place air cap and paste barcode during the
time interval.

P a g e 51 | 91
Original MTM-1 Analysis (Valve Cover): Dual Operators
Symbol Action
description
TMUs(idea
l)
TMUs(idea
l)
1 TMU
W_PO3 bring gasket to
workstation
workstation
W_PO3 51
P3SE position gasket
into pocket
pocket
P3SE 445
W_P5 walk to valve
cover
75 75 walk to valve cover W_P5 75
board
board
R24A 14.9
M24A remove valve
cover board
22.4 22.4 remove valve
cover board
M24A 22.4
G1A pick up valve
cover
2 2 pick up valve cover G1A 2
2 grasp brush G1A 2
27.1 move brush onto
edge of VC
M30A 27.1
W_P5 move to test
station
75 75 move to test station W_P5 75

P a g e 52 | 91
handle
handle
R12A 9.6
handle
handle
G1A 2
M12B lift valve cover up
f =1.17
15.678 15.678 lift valve cover up
f = 1.17
M12B 15.678
W_PO1
2
walk to pallet
w/VC
w/VC
W_PO1
2
204
into pallet
into pallet
M40C 64.7

P a g e 53 | 91
W_P10 walk to valve
cover casting
casting
W_P10 150
casting
casting
G1A 2
W_PO4 walk with cover
casting
casting
W_PO4 60
onto WS f1.17
onto WS f1.17
M16C 21.879
waiting processes
w/cover plc
w/cover plc
334
R24A remove hand
from VC casting
VC casting
R24A 14.9
R20A reach barcode 13.1 13.1 reach barcode R20A 13.1
G4C grasp barcode 12.9 12.9 grasp barcode G4C 12.9
M20C move barcode
onto VC surface
22.1 22.1 move barcode onto
VC surface
M20C 22.1
P2SE paste barcode 16.2 16.2 paste barcode P2SE 16.2
G1A grasp maker 2 22.4 pass marker to left
hand
M24A 22.4
M12B pass marker to
right hand

P a g e 54 | 91
M12B lift up VC casting
f = 1.17
=1.17
M12B 15.678
W_PO2 walk to WS2 w/
VC casting
VC casting
W_PO2 34
f = 1.17
f=1.17
M12C 17.784
Total TMU 2410.699
4
Left Hand
Symbol Action
description
TMUs(idea
l)
TMUs(idea
l)
2 TMU
M14A place roller on
VC top
top
M14A 10.5
side
f=1.17
f=1.17
M12C 17.784

P a g e 55 | 91
W_PO3 walk to WS3 51 51 walk to WS3 W_PO3 51
on WS f=1.17
on WS f=1.17
M14C 19.773
2 grasp brush G1A 2
9.6 hand back to
breather
R12A 9.6
location
11.3 11.3
hand
M14A 14.4
M10C move bolt to
thread
13.5 13.5 move bolt to thread M10C 13.5
M16C place torque gun
to bolt 1
bolt 1
M16C 18.7

P a g e 56 | 91
to bolt 2
bolt 2
M6C 10.3
W_PO4 bring VC to WS4 68 68 bring VC to WS4 W_PO4 68
M16C position VC
f=1.17
21.879 21.879 position VC f
=1.17
M16C 21.879
2 grasp inset G1A 2

P a g e 57 | 91
code
M18A 17.6
5.7 take off marker
head
D1D 5.7
16 mark P1NSE 16
10.6 tighten marker
head
APA 10.6
Total TMU 1960.72
Total Sec 70.58592

P a g e 58 | 91
Improved MTM-1 Analysis (Valve Cover): Dual Operators
Valve Cover (Improved) MTM Analysis (Operator 1)
Symbo
l
Action
description
TMUs(ideal
)
TMUs(ideal
)
1 TMU
W_PO
3
bring gasket to
workstation
workstation
W_PO3 51
P3SE position gasket
into pocket
pocket
P3SE 445
W_P5 walk to valve
cover
75 75 walk to valve cover W_P5 75
board
board
R24A 14.9
M24A remove valve
cover board
22.4 22.4 remove valve cover
board
M24A 22.4
G1A pick up valve
cover
2 2 pick up valve cover G1A 2
2 grasp brush G1A 2
8.1 move brush onto
edge of VC
M6A 8.1
W_P5 move to test
station
75 75 move to test station W_P5 75

P a g e 59 | 91
handle
handle
R12A 9.6
handle
handle
G1A 2
M12B lift valve cover up
f =1.17
15.678 15.678 lift valve cover up f
= 1.17
M12B 15.678
W_PO
4
walk to pallet
w/VC
w/VC
W_PO4 68
into pallet
into pallet
M40C 64.7
TL90 rotate carousel 16.2 16.2 rotate carousel TL90 16.2

P a g e 60 | 91
W_P4 walk to valve
cover casting
casting
W_P4 60
casting
casting
G1A 2
W_PO
4
walk with cover
casting
casting
W_PO4 60
onto WS f1.17
onto WS f1.17
M16C 21.879
waiting processes
w/cover, barcode
w/cover, barcode
334
R24A remove hand
from VC casting
VC casting
R24A 14.9
G1A grasp maker 2 11.8 scan barcode 2 M8C 11.8
12.9 pass marker to left
hand
M12A 12.9
M12B pass marker to
right hand
13.4 return marker M12B 13.4

P a g e 61 | 91
M12B lift up VC casting
f = 1.17
=1.17
M12B 15.678
W_PO
2
walk to WS2 w/
VC casting
VC casting
W_PO2 34
f = 1.17
f=1.17
M12C 17.784
Total TMU 2078.099
4
Valve Cover (Improved) MTM Analysis (Operator 2)
Left Hand
Symbo
l
Action
description
TMUs(ideal
)
TMUs(ideal
)
2 TMU
M14A place roller on
VC top
top
M14A 10.5
side
f=1.17
f=1.17
M12C 17.784
W_PO
3
walk to WS3 51 51 walk to WS3 W_PO3 51
on WS f=1.17
on WS f=1.17
M14C 19.773

P a g e 62 | 91
2 grasp brush G1A 2
9.6 hand back to
breather
R12A 9.6
location
11.3 11.3
hand
M14A 14.4
M10C move bolt to
thread
13.5 13.5 move bolt to thread M10C 13.5
to bolt 1
bolt 1
M16C 18.7
to bolt 2
bolt 2
M6C 10.3

P a g e 63 | 91
W_PO
4
bring VC to WS4 68 68 bring VC to WS4 W_PO4 68
M16C position VC
f=1.17
21.879 21.879 position VC f
=1.17
M16C 21.879
2 grasp inset G1A 2

P a g e 64 | 91
code
M18A 17.6
5.7 take off marker
head
D1D 5.7
16 mark P1NSE 16
10.6 tighten marker
head
APA 10.6
Total TMU 1960.72

P a g e 65 | 91
Original MTM-1 Analysis (Air Intake)
Air Intake MTM Analysis
Sym
bol
Action description TMUs(
ideal)
TMUs(
ideal)
Action description Sym
bol
Operator'
s TMU
R24
A
reach scanner 14.9 12.9 reach label 1 R10
D
14.9
G1A grasp scanner 2 3.5 grasp label 1 G1B 3.5
M30
C
pull scanner to label 1 30.7 8.7 reach label 1 location R10
A
30.7
3.4 3.4 paste label 1 APA
F
3.4
14.2 14.2 reach label 2 R12
D
14.2
3.5 3.5 grasp label 2 G1B 3.5
9.6 9.6 reach label 2 location R12
A
9.6
F
3.4
22.5 22.5 reach label 3 location R24
D
22.5
F
3.4
M30
C
Move Air Intake
Connector to station
30.7 30.7 Move Air Intake
M30
C
30.7
R12
A
reach socket 1 9.6 9.6 9.6
G4B grasp socket 1 9.1 9.1 9.1
P3SE lock socket 1 43 43 43
R12
A
reach socket 2 9.6 9.6 9.6
R24
A
reach scanner 14.9 15.8 reach socket 3 R16
B
15.8
G1A grasp scanner 2 9.1 grasp socket 3 G4B 9.1
M30
C
pull scanner to label 1 27.1 43 lock socket 3 P3SE 43
P2SE scan label 1 16.2 16.2 16.2
M12
C
move scanner to label 2 15.2 15.2 15.2
P2SE scan label 2 16.2 16.2 16.2
M26
C
return scanner 27.3 27.3 27.3

P a g e 66 | 91
R12
A
reach screw adaptor 9.6 14.9 reach torque gun R24
A
14.9
G1C
2
grasp screw adaptor 8.7 2 grasp torque gun G1A 8.7
R30
A
reach torque location 17.5 17.5 17.5
P3SE install screw adaptor 43 43 43
M24
C
move torque gun to
screw 1
25.5 25.5 move torque gun to
screw 1
M24
C
25.5
hold 56 56 hold 56
M3C move torque gun to
screw 2
screw 2
M3C 6.7
hold 56 56 hold 56
screw 3
screw 3
M3C 6.7
hold 56 56 hold 56
screw 4
screw 4
M3C 6.7
hold 56 56 hold 56
D1E loose screw adaptor 4 22.4 return torque gun to
original position
M24
A
22.4
M12
A
return screw adaptor 12.9 12.9 12.9
R28
B
reach DFN pressure
sensor
24.4 24.4 24.4
G1A grasp DFN pressure
sensor
2 2 2
M28
C
move DFN sensor to
location
29 29 29
13.1 13.1 reach scanner R20
A
13.1
2 2 grasp scanner G1A 2
P2SE scan DFN sensor label 16.2 16.2 scan DFN sensor label P2SE 16.2
M26
C
return scanner 27.3 27.3 27.3
R22
A
reach screws 14 14 14
G1B grasp screws 3.5 3.5 3.5
M4A pass one crew to right
hand
6.1 2 grasp screw G1A 6.1
P2SE position screw 16.2 16.2 position screw P2SE 16.2
T720
S
tighten screw 14.8 15.4 tighten screw T720
S
15.4
14.9 14.9 reach torque gun R24
A
14.9
screw 5
M24
C
25.5
56 56 hold 56

P a g e 67 | 91
screw 6
M3C 6.7
56 56 hold 56
22.4 22.4 return torque gun to
original position
M24
A
22.4
R12
A
reach screw adaptor 9.6 9.6 9.6
G1C
2
grasp screw adaptor 8.7 8.7 8.7
R30
A
reach torque location 17.5 17.5 17.5
screw 7
M18
C
20.4
56 56 hold 56
original position
M24
A
22.4
M12
C
return screw adaptor 15.2 15.2 15.2
R14
A
reach air seal 10.5 10.5 reach air seal R14
A
10.5
M7A move air seal 8.9 8.9 move air seal M7A 8.9
P2SS position air seal 19.7 19.7 position air seal P2SS 19.7
3.5 3.5 tighten air seal T45S 3.5
R14
A
reach air test device 10.5 10.5 10.5
M14
A
move air test device 14.4 14.4 14.4
R6A reach socket 7 7 7
G1A grasp socket 2 2 2
P2SE lock socket 16.2 16.2 16.2
TBC
1
turn left 18.6 18.6 turn left TBC
1
18.6
R10
A
reach gasket handlers 8.7 8.7 8.7
M12
C
position 1st gasket
handler
15.2 15.2 15.2
8 8 position 2nd gasket
handler
M4C 8
9.6 9.6 reach gasket R12
A
9.6
2 2 grasp gasket G1A 2
M20
C
move gasket to location 22.1 22.1 move gasket to location M20
C
22.1
R14
A
reach fuel throttle 10.5 10.5 reach fuel throttle R14
A
10.5
G1A grasp fuel throttle 2 2 grasp fuel throttle G1A 2

P a g e 68 | 91
M14
C
move fuel throttle 16.9 16.9 move fuel throttle M14
C
16.9
R10
A
reach screw 1 8.7 8.7 reach screw 2 R10
A
8.7
G1A grasp screw 1 2 2 grasp screw 2 G1A 2
T720
S
position screw 1 14.8 15.4 position screw 2 T720
S
15.4
8.7 8.7 reach screwdriver R10
A
8.7
13.5 13.5 move screwdriver M10
C
13.5
15.4 15.4 tighten screw 2 T720
S
15.4
6.1 6.1 move to screw 1 M4A 6.1
S
15.3
8.7 8.7 return screwdriver M10
A
8.7
R10
A
reach gasket handler 1 8.7 8.7 reach gasket handler 2 R10
A
8.7
M10
C
move handler 1 to 2nd
AI connecter
13.5 13.5 move handler 2 to 2nd
connector
M10
C
13.5
R10
A
reach screw 3 8.7 8.7 reach screw 4 R10
A
8.7
P1SS position screw 3 9.1 9.1 position screw 4 P1SS 9.1
9.6 9.6 reach screwdriver R12
A
9.6
C
15.4
T720
S
tighten screw 3 14.8 14.8 tighten 4 T720
S
14.8
A
11.3
TBC
1
turn back 18.6 18.6 turn back TBC
1
18.6
R30
A
reach air seal 17.5 17.5 reach air seal R30
A
17.5
T45S unload air seal 3.5 3.5 unload air seal T45S 3.5
M7A move air seal aside 8.9 8.9 move air seal aside M7A 8.9
13.1 13.1 reach socket 3 R20
A
13.1
43 43 unlock socket 3 P3SE 43
R20
A
reach testing device 13.1 7 reach testing device R6A 13.1
G1A grasp testing device 2 2 grasp testing device G1A 2
M14
A
return testing device to
location
14.4 14.4 return testing device to
location
M14
A
14.4

P a g e 69 | 91
R16
A
reach socket 1 11.4 11.4 11.4
P3SE unlock socket 1 43 43 43
R6A reach socket 2 7 7 7
W_P
O12
move finished item to
pallet
408 408 move finished item to
pallet
W_P
O12
408
W_P
13
back to station 442 442 back to station W_P
13
442
Total TMU 2823.7
Total seconds 101.6532

P a g e 70 | 91
Improved MTM-1 Analysis (Air Intake)
Air Intake MTM Analysis
Symb
ol
Action description TMUs(ide
al)
TMUs(ide
al)
Action description Symb
ol
Operato
r's TMU
R24A reach scanner 14.9 12.9 reach label 1 R10D 14.9
G1A grasp scanner 2 3.5 grasp label 1 G1B 3.5
M30C pull scanner to label 1 30.7 8.7 reach label 1 location R10A 30.7
3.4 3.4 paste label 1 APAF 3.4
14.2 14.2 reach label 2 R12D 14.2
9.6 9.6 reach label 2 location R12A 9.6
22.5 22.5 reach label 3 location R24D 22.5
M30C Move Air Intake
30.7 30.7 Move Air Intake
M30C 30.7
R12A reach socket 1 9.6 9.6 9.6
R12A reach socket 2 9.6 9.6 9.6
R24A reach scanner 14.9 15.8 reach socket 3 R16B 15.8
G1A grasp scanner 2 9.1 grasp socket 3 G4B 9.1
M30C pull scanner to label 1 27.1 43 lock socket 3 P3SE 43
P2SE scan label 1 16.2 16.2 16.2
M12C move scaner to label
2
15.2 15.2 15.2
P2SE scan label 2 16.2 16.2 16.2
M26C return scanner 27.3 27.3 27.3
R12A reach screw adaptor 9.6 14.9 reach torque gun R24A 14.9
G1C2 grasp screw adaptor 8.7 2 grasp torque gun G1A 8.7
R30A reach torque location 17.5 17.5 17.5
screw 1
screw 1
M24C 25.5
hold 56 56 hold 56
screw 2
screw 2
M3C 6.7
hold 56 56 hold 56

P a g e 71 | 91
screw 3
screw 3
M3C 6.7
hold 56 56 hold 56
screw 4
screw 4
M3C 6.7
hold 56 56 hold 56
D1E loose screw adapator 4 22.4 return torque gun to
original position
M24A 22.4
M12A return screw adapator 12.9 12.9 12.9
R28B reach DFN pressure
sensor
24.4 24.4 24.4
G1A grasp DFN pressure
sensor
2 2 2
M28C move DFN sensor to
location
29 29 29
13.1 13.1 reach scanner R20A 13.1
2 2 grasp scanner G1A 2
P2SE scan DFN sensor
label
16.2 16.2 scan DFN sensor
label
P2SE 16.2
M26C return scanner 27.3 27.3 27.3
R22A reach screws 14 14 14
G1B grasp screws 3.5 3.5 3.5
M4A pass one crew to right
hand
6.1 2 grasp screw G1A 6.1
P2SE position screw 16.2 16.2 position screw P2SE 16.2
T720
S
tighten screw 14.8 15.4 tighten screw T720
S
15.4
14.9 14.9 reach torque gun R24A 14.9
screw 5
M24C 25.5
56 56 hold 56
screw 6
M3C 6.7
56 56 hold 56
original position
M24A 22.4
R12A reach screw adaptor 9.6 9.6 9.6
G1C2 grasp screw adaptor 8.7 8.7 8.7
R30A reach torque location 17.5 17.5 17.5
screw 7
M18C 20.4
56 56 hold 56
original position
M24A 22.4
M12C return screw adapator 15.2 15.2 15.2
R14A reach air seal 10.5 10.5 reach air seal R14A 10.5

P a g e 72 | 91
M7A move air seal 8.9 8.9 move air seal M7A 8.9
P2SS position air seal 19.7 19.7 position air seal P2SS 19.7
3.5 3.5 tighten air seal T45S 3.5
R14A reach air test device 10.5 10.5 10.5
M14A move air test device 14.4 14.4 14.4
R6A reach socket 7 7 7
G1A grasp socket 2 2 2
P2SE lock socket 16.2 16.2 16.2
TBC1 turn left 18.6 18.6 turn left TBC1 18.6
R10A reach gasket handlers 8.7 8.7 8.7
M12C position 1st gasket
handler
15.2 15.2 15.2
8 8 position 2nd gasket
handler
M4C 8
9.6 9.6 reach gasket R12A 9.6
2 2 grasp gasket G1A 2
M20C move gasket to
location
22.1 22.1 move gasket to
location
M20C 22.1
R14A reach fuel throttle 10.5 10.5 reach fuel throttle R14A 10.5
G1A grasp fuel throttle 2 2 grasp fuel throttle G1A 2
M14C move fuel throttle 16.9 16.9 move fuel throttle M14C 16.9
R10A reach screw 1 8.7 8.7 reach screw 2 R10A 8.7
T720
S
position screw 1 14.8 15.4 position screw 2 T720
S
15.4
8.7 8.7 reach screwdriver R10A 8.7
C
13.5
S
15.4
6.1 6.1 move to screw 1 M4A 6.1
S
15.3
A
8.7
R10A reach gasket handler 1 8.7 8.7 reach gasket handler 2 R10A 8.7
M10
C
move handler 1 to 2nd
AI connecter
13.5 13.5 move handler 2 to 2nd
connector
M10
C
13.5
R10A reach screw 3 8.7 8.7 reach screw 4 R10A 8.7
P1SS position screw 3 9.1 9.1 position screw 4 P1SS 9.1
9.6 9.6 reach screwdriver R12A 9.6

P a g e 73 | 91
C
15.4
T720
S
tighten screw 3 14.8 14.8 tighten 4 T720
S
14.8
A
11.3
TBC1 turn back 18.6 18.6 turn back TBC1 18.6
R30A reach air seal 17.5 17.5 reach air seal R30A 17.5
T45S unload air seal 3.5 3.5 unload air seal T45S 3.5
M7A move air seal aside 8.9 8.9 move air seal aside M7A 8.9
13.1 13.1 reach socket 3 R20A 13.1
43 43 unlock socket 3 P3SE 43
R20A reach testing device 13.1 7 reach testing device R6A 13.1
G1A grasp testing device 2 2 grasp testing device G1A 2
M14A return testing device to
location
14.4 14.4 return testing device to
location
M14A 14.4
R16A reach socket 1 11.4 11.4 11.4
R6A reach socket 2 7 7 7
W_PO1
2
move finished item to
pallet
408 408 move finished item to
pallet
W_PO1
2
408
W_P13 back to station 442 442 back to station W_P13 442
Total TMU 2823.7
Total seconds 101.6532

P a g e 74 | 91
Gantt Chart

P a g e 75 | 91
Team member resumes

P a g e 76 | 91

P a g e 77 | 91

P a g e 78 | 91

P a g e 79 | 91

P a g e 80 | 91
Accounting of hours worked on the project to-date
• Saturday, 8/31. 2:00 P.M. - 4 P.M.
• Recorded by Mani Kumar
• Members in Attendance:
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary connected through instant messaging
o Mani Kumar
• Summary:
o Discussed scheduling conflicts and found times of the week that works for
everyone.
o Finished team charter in a smooth manner to encourage involvement.
o Researched company and used Google Earth 3D to analyze Telamon Industrial
Solutions building in Carmel, IN, to understand the layout, docking, etc. (Rough
Research)
o We sent a follow-up email asking about first-interaction concerns regarding
safety, logistics, and scheduling. We also scheduled the first meeting date for
9/13.
• Tuesday, 9/3. 2:00 P.M. - 4:15 P.M
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary
o Mani Kumar
• Summary (in chronological order):
o Started creating separate documents:
§ Questions for the first client meeting
§ Access
§ Current situation
§ Objective
§ Resources
§ Company organization.
§ Questions for the first meeting with operators.
o Created a Project Proposal Report Draft.
• Thursday, 9/5, 2:00 PM - 4:15 PM

P a g e 81 | 91
• Recorded by David Chen
• Members in attendance:
o David Chen
o Joseph Zakhary
o Mani Kumar
• Summary:
o Finalized and sent the list of questions to Telamon.
o We discussed the trip to Telamon on 9/13.
• Tuesday 9/10, 6:00 P.M. – 9:00 P.M.
• Planned meeting, but only Hao Ma was able to attend due to IR.
• Summary:
o Discussed the attachments in the Telamon reply.
o Extracted key information from the files
• Friday 9/13, 9 A.M – 1 P.M.
• Recorded by Joseph Zakhary, Mani Kumar
• Members in attendance:
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary
o Mani Kumar
• Summary:
o Drove down to Telamon Industrial Solutions for first in-person meeting and
observation of the assembly lines.
o Some notes were taken down during conversation with Jason Hale:
§ High runners - High volume production
§ Uncertainty regarding staffing for Valve Cover assembly line - 1 or 2
persons
§ Communication issues on the assembly line. There are at least seven
different languages spoken on the production floor. Tackled by using
visual aids or translators.
§ Standardization sometimes missing because operators try to meet
satisfactory standards without a protocol.
§ Idle time while testing, roughly a minute?
§ From the way Jason was talking, the operators seem not to care enough/be
satisfied with the work. Usually, operators in menial labor do not have

P a g e 82 | 91
enough incentive to follow protocol. An incentive could include a stricter
protocol to be introduced, a production cap/day?
§ 1-piece flow. Assembly-Testing-Release.
§ Needs consistency w.r.t variant parts/families.
§ Cummins requires the part. Assembly procedure created by Telamon.
§ Air intakes
• Testing in the same fixture
§ Valve Covers
• Four stations
• One cell
• Two operators
o Two stations/operator
• U-shaped
§ All approvals go through Cummins. Major changes like changing
positions of machines require approval.
o Issues:
§ Operators driving long times to get to work
§ Training
• Work instruction (visual aids)
• Trained the same way
§ Total of 7 languages
• Communication issues
• Normally someone to act as a translator
§ Testing
• The current SOP did not specify how to use the waiting time
during automated testing.
o Fill
o Stabilize
o Testing
o Exhaust
§ Process
• Assembly
• Test
• Packaging
§ Similar parts back-to-back
• Clear cell after each run
§ Telamon designing the assembling process
• Cummins only provides the print
§ Project focus: Process standardization and not assembly rewrite.
• Only assembly

P a g e 83 | 91
• Manage inventory
• Valve from continental
• PPAP, moving anything, must be approved by CUMMINS
(Production part approval process)
o Problems:
§ Cells with OT, meaning additional costs
§ High orders from Cummins
§ High runner standardization
• Air intake and valve cover families
o Action items
§ Schedule of operators
§ # of operators running the cell
§ Benchmark to G
§ Ask all questions at once
§ Efficiency
§ Database for traceability
• Proposal
§ Always standing
§ Cell 1 - valve covers
§ Cells 6, 7, 8 - air intake
• Wednesday 9/18, 3:00 P.M. – 5 P.M.
• Recorded by Avishek Ray
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary worked remotely
o Mani Kumar worked remotely
• Summary:
o After watching all the presentations on Tuesday, 9/17, we made changes to the
PowerPoint and talking points.
o Divided parts of the presentation among team members to be spoken during the
presentation on Thursday, 9/19.
• Thursday 9/19, 2:00 P.M. – 3 P.M.
o Avishek Ray
o David Chen

P a g e 84 | 91
o Hao Ma
o Joseph Zakhary
o Mani Kumar
• Summary:
o Made final revisions to PowerPoint presentation for the presentation at 4 PM the
same day.
o Performed a few trial runs of the presentation and through feedback by the group,
improved and updated presentation points.
• Thursday 9/20, 2:00 P.M. – 3 P.M.
o David Chen
o Hao Ma
o Joseph Zakhary
o Mani Kumar
• Summary:
o The team visited Telamon for additional data collection.
• Saturday 9/21, 3:00 P.M. – 6 P.M.
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary connected through instant messaging
o Mani Kumar
• Summary:
o We continued working on the project proposal document.
o Team members took up portions of the project based on their relevance to their
findings.
• Saturday 9/22, 3:00 P.M. – 6 P.M.
o Avishek Ray
o David Chen
o Hao Ma
o Mani Kumar worked remotely
• Summary:

P a g e 85 | 91
o The team finalized the proposal document together.
• Tuesday 9/24, 2:00 P.M. – 4:15 P.M.
o Avishek Ray
o David Chen
o Hao Ma
o Joseph Zakhary
• Summary:
o Formulated additional questions and data requests for Telamon.
• Saturday 9/28, 2:30 P.M. – 4:00 P.M.
o Avishek Ray
o David Chen
o Hao Ma
• Summary:
o Discussed requirements for status report 1.
o We divided up work among team members to ensure timely completion.
o Worked on updating the recommended approaches and system model.
• Thursday 10/3, 2:00 P.M. – 4:00 P.M.
o Avishek Ray
o David Chen
o Joseph Zakhary
o Mani Kumar
• Summary:
o Addressed potential modifications to the proposal to create a foundation for status
report 1.
o Discussed and resolved some internal concerns regarding the team and Telamon
with Prof. Kotterman.
• Saturday 10/5, 1:00 P.M. – 4:00 P.M.
o Avishek Ray

P a g e 86 | 91
o David Chen
o Mani Kumar
• Summary:
o Added risks to the recommended approaches.
o We have added quantitative analysis to the expected results.
o Addresses potential obstacles to proposed solutions and plans to tackle them.
o Finalized status report 1.
• Saturday 10/14, 9:00 A.M. – 12:00 P.M.
o Avishek Ray
o David Chen
o Mani Kumar
o Hao Ma
• Summary:
o Visited Telamon to access the QC process from all appropriate cells.
o The team spoke to QC employees and learned about how training of operators and
QC of parts work.
o Sketched rough spaghetti diagrams from appropriate cells.
• Tuesday 10/15, 3:00 P.M. – 4:15 P.M.
o Avishek Ray
o David Chen
o Mani Kumar
o Hao Ma
o Joseph Zakhary
• Summary:
o Finished individual and team assignments for team evaluation.
• Wednesday 10/16, 4:30 P.M. – 6:30 P.M.
o Avishek Ray
o David Chen
• Summary:
o Met with faculty mentor Prof. Nof to learn about several additional considerations
and recommendations that the team should make going forward.

Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation Report

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