Recommended
More Related Content
What's hot
What's hot (19)
Similar to Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation
Similar to Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation (20)
Recently uploaded
Recently uploaded (20)
Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation
- 1. TELAMON AIR INTAKE & VALVE COVER SUBASSEMBLY LINE IMPROVEMENT PROPOSAL Team 28: Avishek Ray, David Chen, Hao Ma, Joseph Zakhary, Mani Kumar Client: Telamon Industrial Solutions Location: Carmel, IN Faculty Mentor: Prof. Shimon Y. Nof Course Mentor: Maithilee Motlag Client Contact: Jason Hale
- 2. AGENDA • Problem statement • Methodology • Analysis and Findings • System Model • Results • Discussion • Reflection
- 3. PROBLEM STATEMENT The Air Intake & Valve Cover subassembly lines need to reduce overtime and improve standardization to face the challenge of large customer order quantity. The formal problem statement is: “The Optimization and Standardization of the Air Intake and Valve Cover Subassembly lines at Telamon Industrial Solutions to increase work efficiency and improve production rates by about 10-15%.”
- 4. METHODOLOGY
- 5. Observation • Evident bottlenecks in the assembly process • Opportunities to improve efficiency on the production lines Operator Interviews • Production specific questions • Feedback on their pain points during assembly Ergonomic Analysis • MTM-1 Analysis/Time studies • Dassault CATIA reach envelope analysis
- 7. MTM-1 & ERGONOMIC ANALYSIS FINDINGS: VALVE COVER CELL • Collecting and pasting barcode should be done during gasket-press automation • Gluing should start from right edge of valve cover castings
- 8. MTM-1 & ERGONOMIC ANALYSIS FINDINGS: AIR INTAKE CELL • Pre-tightening of bolts on air connector with screwdriver is unnecessary • Side desk of workstation is out of reach distance • Unnecessary walking during assembly procedure • Gaskets are difficult to reload
- 9. Ergonomic improvements Industrial 4.0 developments • Optimized tray for gaskets and screws • Exit pallet carousel • Shorter reach distance design • Production coordination software or remote- controlled bingo board • Post Assembly machine vision QC
- 11. Exit Pallet Carousel Optimized tray for the gaskets and screws Reduces unergonomic reach and assembly time CATIA model of an optimized workstation based on reach analysis Walmart inspired packaging technique to improve efficiency in filling up pallets post assembly
- 13. Production Coordination Software/ remote-controlled Bingo Board Post Assembly Machine Vision QC VS2 Samsara Guide Optimizing production using Andon Studios software Line assist signals for better floor communication Seamless QC performed by VS2 Samsara mounted overhead the packaging pallet VS2 Samsara
- 14. SYSTEM MODEL
- 15. Cell 2700 With post-assembly Machine vision QC Cell 2000 With post-assembly Machine vision QC Cell 2600 With post-assembly Machine vision QC Supplies Parts to Rejected Parts Rejected Parts Air intake Valve Cover Rejected Parts Defective Parts Has price authority over Quality Defective Parts Telamon Warehouse @ Carmel, IN Parts Suppliers Cummins 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)
- 16. RESULTS
- 17. Improvements Projected savings (USD/year) Optimized Gasket tray 16 𝑚𝑖𝑛 ℎ𝑟 10 ℎ𝑟𝑠 𝑑𝑎𝑦 ∗ $ 15 ℎ𝑟 ∗ 10 𝑤𝑜𝑟𝑘𝑒𝑟𝑠 ∗ 230 𝑑𝑎𝑦𝑠 𝑦𝑟 = $𝟗𝟏𝟗 𝒚𝒓 Rotating pallet carousel 33 600 ℎ𝑟 ∗ $15 ∗ 10 𝑤𝑜𝑟𝑘𝑒𝑟𝑠 ℎ𝑟 ∗ 230𝑑𝑎𝑦𝑠 𝑦𝑟 = $𝟏, 𝟖𝟗𝟖 𝒚𝒓 Andon Studio 101 ℎ𝑟 𝑦𝑟 ∗ $15 ∗ 10 𝑤𝑜𝑟𝑘𝑒𝑟𝑠 ℎ𝑟 = $𝟏, 𝟓𝟏𝟓 𝒚𝒓 Post-assembly machine vision QC $15 ∗ 10ℎ𝑟 ∗ 2𝑤𝑜𝑟𝑘𝑒𝑟𝑠 ℎ𝑟 ∗ 230𝑑𝑎𝑦𝑠 𝑦𝑟 − ($3,500 ∗ 8𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 + $350𝑎𝑛𝑛𝑢𝑎𝑙 𝑙𝑖𝑐𝑒𝑛𝑠𝑒 𝑓𝑒𝑒) = $𝟒𝟎, 𝟔𝟓𝟎 𝒚𝒓
- 18. 24% 48% 4% 24% PERCENTAGE TIME SAVED BY EACH SOLUTION PER WORKSTATION 435 365 0 100 200 300 400 500 Current Production Time Improved Production Time Minutes Overall Time Savings in a workday 9% 31% 16% 44% PERCENTAGE COST SAVED BY EACH SOLUTION IN A YEAR 16% reduction in time
- 19. DISCUSSION • Concerns about installing the pallet carousel • Safety • Opposition on necessity grounds • Concerns about installing the production floor info system • Additional server investment • Fragile monitoring devices (tablets and iPads) on the work floor • Additional training required to use the system • Concerns about installing the machine vision technology • Proper placement and detection of required QC instructions • Potential adjustments in barcode placements to be detected by the technology
- 20. REFLECTIONS
- 21. What we enjoyed Acknowledgments • Being able to work with a real client problem • The freedom to brainstorm solutions based on the learnings from our previous courses • The support of our client, our professors and our faculty mentor throughout the semester We would like to extend our sincere gratitude and appreciation towards Telamon for giving us the opportunity to work on such an intriguing project! It was a pleasure working with Jason Hale through this semester and we would like to thank him for his transparency and prompt responses to all our questions! Also a huge thank you to everyone at Telamon who has made our senior design experience so rewarding ! Key Learnings and Takeaways • Difference between class and industrial expectations • Scope creep and understanding the key pain points being asked to be solved in the project • Working cohesively as a team and settling disputes amicably • Responsibilities of an Industrial engineer in the work force
Editor's Notes
- Thank you Mani! To tackle our case our approach was divided into ergonomic improvements and industrial 4.0 improvemnst
- Thank you Mani! To tackle our case our approach was divided into ergonomic improvements and industrial 4.0 improvemnst
- As we observed the lines and production workstations during our visits at Telamon, we noticed an opportunity to improve the gasket holders in the air intake workstations. Secondly a rotating carousel would increase production and packaging efficiency as well! Lastly we also conducted a CATIA reach analysis to understand if everything in the workstation is within industrial reach boundaries We also considered Industrial 4.0 developments for our client and looked at a production coordination system as well as a post assembly machine vision QC
- After vetting multiple companies such as Cognex omron and samasara, we narrowed down on the VS2 samsara model as it seemed to satisfy the overall QC needs of our client! We also contacted the company to get a quote on the solution and built a relationship with them which Telamon could pick up if they do consider implementing the solution!