1. Auld Technologies LLC Facilities Planning Project Final Presentation Kramer Voigt Austin Mount-Campbell RahulBansal Ahsan Aziz

2. Company Background Auld Technologies LLC is a global market leader in decorative badging, decorative trim and performance decorative coatings. Auld currently supplies market leaders in the consumer electronics, sporting goods, automotive, packaging and plumbing industries. Mission:Auld Technologies is dedicated to producing innovative solutions of the highest quality, with unique value for worldwide customer satisfaction. ISO- 9001 Certified

3. Suggestion #1: Ergonomics Problem: Bending all the way over to get to bottom of racks Largest Flow Area in facility, equals hundreds or reps in bending Solution: Since no other rack styles are on the market, avoid bottom of the rack when possible.

4. Suggestion #2: Plot cutter removal With the added space, could add a new punch and shear machine due to increased production schedules. Plot cutter is in the middle of all the product flows New location: lunch/break room of future printing location

5. Suggestion #3: Material Handling All the material handling between the work centers is done manually by hand Due to manual handling a batch size of 30 sheets is used when moving from one work center to the next. Using small boxes or carts allows us to increase the batch size to 200. #Old trips : 33 #New trips : 5 Old Distance moved= 465ft x 33=15345ft New distance moved= 465ft x 5=2325ft Old operator motion waste= 15345/(4.4 ft/sec)=3487.5 sec New operator motion waste = 2325/4.4= 528.40 sec Operator motion waste cut by 85%. (Saved 42mins ) Benefit: This reduces operator motion waste as well as reduces physical stress on a worker and speeds up the material handling.

6. Suggestion #4: Safety : Slips, trips and falls The center of the facility was over packed by machines, WIP and empty boxes lying on the floor which made it very hard to travel across the facility and caused slips and trips. Save $1,150 / worker in form of fine by OSHA. Slips, trips, and falls can cause back injuries, strains and sprains, contusions, and fractures. With around 8 people passing through this area back and forth a lot of workers can get injured. The plot cutter covered an area of approximately 64sqft. With the plot cutter gone we have free space which we can utilize to place an additional shelf or storage to clear the mess on the floor

7. Suggestion #5: Organize Throw away old unused items Welding Machine moved and OSHA required wall installed There are labeled shelves for finished product Pallets should be in shipping receiving with pallet jack One maintenance worker yet three drill presses? 110ft / 4.4 ft/sec= 25 sec/box * 6 boxes * 2= 5 min lost plus search time for being in wrong location 80 ft / 4.4 ft/sec= 18.2 sec/pallet * 2 pallets = 36 sec plus search time for pallets being in wrong location Like drill presses sell for over $400 each. Average OSHA fine of $2300.00.

8. Suggestion #6: Finished good Storage Empty Boxes lying along with finished products and taking up space Because of this Maintenance shop has left over finished products lying on floor This one shows how easy it would become if all the finished products are arranged together The company has a daily production of 1000 sheets and so handling and storing is very important. If sheets get damaged or misplaced or wrong shipment done can cost heavily to them. Losses then will be per sheet $10 * 30(educated guess) = $300/day BENEFITS: Better flow, Easy access of finished goods. Shipping them becomes easier. Materials are not destroyed and a lot of cost and time and space is saved. Also now there is space in maintenance room which can be used for company’s essential work Also saves cost and time of an individual who is doing this un required task. Monthly saving time= I day of a worker and cost saved is around $30. Extra time used: distance moved for moving finished boxes to maintenance room = 140ft * 10 times = 1400ft and so the operator motion waste = 1400/4.4ft/sec = 320 sec The company has a high production capacity and so storage is an essential part for them.

9. Suggestion #7: Other Building Demo By removing the wall we increase the space on each side of the line by 3ft This results in 6 ft of space on the far wall and excess of 10 feet on the near wall Ability to inspect before adding the next color Remove this this room Thus, we will exceed OSHA requirements of 3 feet: this adds to comfort and the safety of operator Decreases the product flow time by 20% because inspect times decrease at the end of the product cycle Since they have a crew already coming in to clean existing area, wont be expensive to knock the wall down

10. Suggestion #8: Old office Space Shifted Lunch and break loom to main office Old Layout Placing plot cutter over there BENEFITS Lunch and Break room is 275sq ft and main office area if 912 sq ft. Thus we see how much area is wasted for no reason Plot cutter which occupies 64sq ft was initially placed in different building occupying 81sq ft of space. This space is now used for better material flow. Also saving 81*$20 = $1620 on space. Main office has windows which is good for workers moral. This will decrease health problems and increase their stamina. Around 5 people work in this area and so health cost reduced by 5*50(approx) = $250 on intervals. Also OSHA can fine $250 if workers health not taken care of 0$ cost required for this change. Just minimum cost required for moving plot cutter from one place to another. Land cost today is $20 per sq foot and so we save, 275*$20 = $5500 by shifting lunch and break room to main office. New Layout

11. Suggestion #9: Avoid Outsourcing They outsource embossing of car kick panel trim To outsource requires: Extra hole punches, shipping their and back, charge to emboss. Again estimating half the cost of production goes to outsourcing. Kick panel trim cost $6-$30 after market. GM is intimating at annual sales of up to 100,000 of the Camero. Mean 200,000 door panel emblems. Embossing requires RF press which cost around $10,000 Auld would not provide price but we estimate several dollars a kick panel trim as cost for GM. In conclusion: .75*2*200000= 300000/2= 150000 > 10000. Outsourcing costs an estimated 1400000 Auld cost is estimated to be around 75% of sales cost. Conservatively 75 cents

12. Suggestion #10: Improve Inspection Times Slowest part of process is the inspection processes Inspection time cut by at least 5hrs/day The value stream map shows that inspection is done only once at the end. The C/t for inspection is the highest (36sec/sheet). The drying process after printing takes about 45-60 mins. This is non value added time. We can add value to this time by inspecting sheets while they are drying. The highest # of defects are in the printing of decals and thus by inspecting after printing while the sheets are drying we would cut the inspection time by at least one half (i.e 36/2 = 18secs). With a daily production of about 1000 sheets and new C/t of 18 seconds/sheet we will save 18x 1000 = 18000secs or 5 hrs of inspection each day.