(Student assignment) riordan manufacturing process improvement final

1. Process Improvement
Kirsten Coombs, Charles James, Rebecca Sanchez, Harry Tharp
OPS/571
May 5, 2014
John Ulveling

2. Introduction
Riordan Manufacturing actively implements Six Sigma
Break Apart Current Process
Improve Current Process
Implement New Process

3. DMAIC Process for Electric Fans
DEFINE
DMAIC

4. Electric FansNew Process Design
A. Make-to- Stock Fans
B. Custom- Made Fans
1. Polymer parts are created
2. Assembly of all parts
3. Assembled fans are packaged
1. Custom Design Fans are Developed
2. Manufacture Only a Few
3. Manufacture Small Amount
4. Test Fans and Sell to Customer
2a. Assess production cost
3a. Assess design deviation
(University of Phoenix, 2013)

5. Bottlenecks in New Process
Unexpected variations in the assemble and packaging phase
Understanding the process, continuous monitoring, and managerial support
Failure to meet goals and deadlines
Single most event that creates bottlenecks
Parts shortage
Importance of missing deadlines

6. Bottlenecks in New Process
Poor estimates on process design and production cost
Poor planning and execution leads to bottlenecks
Incorrect production cost estimates cause process design failure
Bottlenecks delay processes and disrupts supply chain

7. TQM tools towards Process Improvement
1Focus Groups
2Flow Charts
3Tree Diagram

8. Why TQM Tools Help
1Focus Groups: Customer insight prior to implementation
2Flow Charts: Identify bottlenecks and other issues
3Tree Diagrams: Organizational structure and each responsibility

9. Project Plan: Make to Stock Fans
Made to stock fans
Duration
Item
Role
Deliverable(s)
M1
Day 1
Polymer parts creation
Manufacturing
Parts created to spec from engineering team with less than 2% error/resubmit rate.
A1
Day 1 -2
Assembly team -retool & refit
Assembly team
Attend retool & refit class on new assembly techniques.
A2
Day 2 -4
Assembly team -new teams
Assembly team
Reorg teams into layered assembly teams to fall inline with item A1
A3
Day 4+
Assembly team -Start new assembly process
Assembly team
Execute item A1's new process with A2 teams
P1
Day 1 -2
Packaging team -new packing process
Packaging team
Attend new packaging class for parts from M1 and A1
P2
Day 2+
Packaging team -execution of process
Packaging team
Start packaging M1 and A1 deliverables for shipping.

10. Project Plan Gantt Chart: Make to Stock Fans

11. Project Plan: Custom Made Fans
Custom made fans
Duration
Item
Role
Deliverable(s)
SA1
Day 1
Custom fan design development
Special Acct team
Specs received by Special Accounts team on new fan design.
E1
Day 1 -2
CAD custom design for 3D printer team
Engineering team
SA1 specs are printed and milled to less than 2% error rate.
E1
Day 2
Deliver printed parts to assembly teams
Assembly team
Printed parts are delivered to assembly teams A1 in custom batch lots
PC1
Day 1 -2
Production cost assessment
Production Cost team
Assess production costs, report to management
T1
Day 1 -2
Testing team process start
Test team
Test new design, report findings to E1 and management
E1
Day 2+
Engineering team -defect report
Engineering team
Report defects from T1 submission. If below 4% send to warehouse and email sales team
S1
Day 2+
Sales team -sell produced inventory
Sales team
If E1 report is ready for sale take inventory report and start customer contact for sales process

12. Project Plan Gantt Chart: Custom Made Fans

13. Conclusion
Time is Money!!!
Identified Antiquated Process as Inefficient
Process Improvements were Implemented
New Process Shortens Manufacture Time
Constant Evaluation and Improvement

14. Reference Page
University of Phoenix. (2013). Riordan Manufacturing Operations: Supply Chain –
Hangzou, China. Retrieved from
https://ecampus.phoenix.edu/secure/aapd/CIST/VOP/Business/Riordan/
Ops/SupplyChain.asp?hangzhou