1 BOWLING GREEN STATE UNIVERSITY College of Technology TECH 626 (Spring 2001)

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BOWLING GREEN BOWLING GREEN STATE UNIVERSITY STATE UNIVERSITY

College of TechnologyCollege of Technology

TECH 626TECH 626 (Spring 2001)(Spring 2001)

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TECH-626 TEAM TECH-626 TEAM PROJECTPROJECT

Phase-2 (final) Phase-2 (final) PresentationPresentation

LEC Rotational Molding Machine

Quality & Reliability

Assessment

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TEAM MEMBERSTEAM MEMBERS

Steve GormleySteve Gormley

Diane PatinoDiane Patino

Chandana HewavitharanageChandana Hewavitharanage

INSTRUCTORINSTRUCTOR

Dr.J.W.Sinn Dr.J.W.Sinn (Professor-College of Technology, BGSU)(Professor-College of Technology, BGSU)

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THE ROTATIONAL MOLDING THE ROTATIONAL MOLDING SECTION’SSECTION’S

CURRENTCURRENT OPERATIONS OPERATIONS

The Rotational Machine Operation Area The Rotational Machine Operation Area (pic 01)

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The Rotational Molding MachineThe Rotational Molding Machine (pic 02)(pic 02)

THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont .cont .

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The Rotational Molding Machine – cont.The Rotational Molding Machine – cont. (pic 03)(pic 03)


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The Rotational Molding Machine - cont.The Rotational Molding Machine - cont. (pic 04)(pic 04)


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The Rotational Molding Machine – cont.The Rotational Molding Machine – cont. (pic 05)(pic 05)

THE ROTATIONAL MOLDING SECTION’S THE ROTATIONAL MOLDING SECTION’S CURRENTCURRENT OPERATIONS OPERATIONS - - cont . cont .

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Molded LEC BodyMolded LEC Body

Molded Body

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PRODUCT DESCRIPTIONPRODUCT DESCRIPTION

The Acme Lifeline Emergency Cart (LEC) is The Acme Lifeline Emergency Cart (LEC) is a fully functional crash cart designed from a fully functional crash cart designed from the ground up to meet the critical demands the ground up to meet the critical demands of a hospital “code.” A “code” is among the of a hospital “code.” A “code” is among the most critical of all hospital emergencies. most critical of all hospital emergencies. Efficient code response saves time and lives, Efficient code response saves time and lives, and that is where a LEC unit comes into and that is where a LEC unit comes into play.play.

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LEC’s FEATURESLEC’s FEATURES Quick, safe transport of vital supplies to the code sites.Quick, safe transport of vital supplies to the code sites. Simultaneous access by multiple code team members.Simultaneous access by multiple code team members. Self-contained vehicle, perfect for medical / surgical floors where Self-contained vehicle, perfect for medical / surgical floors where

vital equipment may not be readily available.vital equipment may not be readily available. Clear, logical organization and identification for all types of Clear, logical organization and identification for all types of

supplies.supplies. Convenience features include integrated backboard, gel bin and I. Convenience features include integrated backboard, gel bin and I.

V. bins.V. bins. Advanced design polymer materials are rugged, durable, yet Advanced design polymer materials are rugged, durable, yet

lightweight, rustproof and easy to clean.lightweight, rustproof and easy to clean. Fully enclosed unit with visible security checks.Fully enclosed unit with visible security checks.

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PROBLEM STATEMENTPROBLEM STATEMENT Acme’s Lifeline Emergency Cart (LEC) assemblyassembly

line resembles a traditional batch and queue operation.

Due to competition and rising production costs, Acme is forced to implement new systems and approaches to increase productivity and quality at lower cost.

Team has selected Rotational Molding Machine operations, a critical area of current operations, and will present a proposal to improve quality and productivity.

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OBJECTIVESOBJECTIVES Improve Safety and ErgonomicsImprove Safety and Ergonomics - Improve GSIC score by 90%- Improve GSIC score by 90% - Improve 5S Score by 425% to achieve 85% - Improve 5S Score by 425% to achieve 85% Improve QualityImprove Quality - Reduce scrap by 85%- Reduce scrap by 85%

- Determine Process Capability- Determine Process Capability - Redesign Product according to Process- Redesign Product according to Process Capability where neededCapability where needed - Improve Process Capability where needed - Improve Process Capability where needed (warp & shrink?)(warp & shrink?) - Achieve and maintain a minimum of 1.33 CPK of - Achieve and maintain a minimum of 1.33 CPK of all Critical to Quality Parametersall Critical to Quality Parameters

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OBJECTIVES OBJECTIVES – cont.– cont.

Reduce Costs with new techniques

-Reduce scrap by 85% Acquire proper tooling

Develop Preventive Maintenance System

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MAJOR STEPSMAJOR STEPS

1. Thorough data collection and analysis 1. Thorough data collection and analysis of Acme’s LEC Roto-Molding Machine of Acme’s LEC Roto-Molding Machine Station.Station. 2. Propose preliminary quality 2. Propose preliminary quality improvementsimprovements 3. Calculate Return on Investment 3. Calculate Return on Investment 4. Decide on proposed improvements4. Decide on proposed improvements 5. Develop training curriculum5. Develop training curriculum cont.cont.

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MAJOR STEPS MAJOR STEPS (cont.)(cont.)

6. Detail Improvements6. Detail Improvements

7. Implement7. Implement

8. Feedback Analysis8. Feedback Analysis

9. Sustain9. Sustain

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GENERAL GENERAL INDICATORS/ INDICATORS/

CHARACTERISTICSCHARACTERISTICS

Safety and Ergonomics:Safety and Ergonomics: Worker fatigueWorker fatigue Heavy toolingHeavy tooling Location of materialsLocation of materials Movements Movements Worker morale andWorker morale and overall safety through 5 “S”overall safety through 5 “S”

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GENERAL INDICATORS/ GENERAL INDICATORS/

CHARACTERISTICS CHARACTERISTICS - -

contcont..Quality:Quality: Better finishing lookBetter finishing look Wastage of materialsWastage of materials Handling of productsHandling of products Workers knowledge in quality functions Workers knowledge in quality functions Worker morale in quality improvementsWorker morale in quality improvements Quality standardsQuality standards

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CHARACTERISTICS CHARACTERISTICS

cont .cont .Reduce Costs :Reduce Costs : Recognizing non-value added processes and Recognizing non-value added processes and

eliminating them accordinglyeliminating them accordingly Reduction of materials wastages through proper Reduction of materials wastages through proper

handling and methodshandling and methods Better productivity levels to reduce unnecessary time Better productivity levels to reduce unnecessary time

through SOPsthrough SOPs (Quality Management)(Quality Management) Reduce defect rates through proper quality standards Reduce defect rates through proper quality standards

( Quality Management)( Quality Management)

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CHARACTERISTICS CHARACTERISTICS – –

contd .contd . Decrease Cycle Time:Decrease Cycle Time: Wasted movementsWasted movements Poorly located toolingPoorly located tooling Unorganized work stationUnorganized work station

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GENERAL INDICATORS/ GENERAL INDICATORS/ CHARACTERISTICS CHARACTERISTICS

– contd .– contd .Develop Preventive Maintenance: Develop Preventive Maintenance:

* Excessive trainingExcessive training

* Introduction of better PM * Introduction of better PM

methodsmethods

* Introduction of Preventive * Introduction of Preventive

Maintenance Management Maintenance Management

SystemsSystems

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STATISTICAL ANALYSISSTATISTICAL ANALYSIS

0.1600.1550.1500.1450.1400.1350.1300.1250.1200.1150.110

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10

0

C2

Fre

qu

ency

Finger Guard Wall Thickness - "B" Zone

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STATISTICAL ANALYSIS STATISTICAL ANALYSIS CONTD.CONTD.

0.180.170.160.150.140.130.12

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10

5

0

C3

Fre

qu

ency

Finger Guard Wall Thickness - "C" Zone

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0 10 20

0.140

0.145

0.150

0.155

Xbar and R Chart

Subgr

Me

an

1

Mean=0.1464

UCL=0.1556

LCL=0.1371

0.00

0.01

0.02

0.03

Ra

nge

1

R=0.01605

UCL=0.03395

LCL=0

0 10 20

Last 20 Subgroups

0.13

0.14

0.15

0.16

Subgroup Number

Va

lue

s

0.1 0.2

Capability PlotProcess Tolerance

I I I

I I I

I ISpecifications

Within

Overall

0.13 0.15 0.17

Normal Prob Plot

0.12 0.14 0.16

Capability Histogram

WithinStDev:Cp:Cpk:

0.00690232.412.24

OverallStDev:Pp:Ppk:

0.00699762.382.21

LEC Finger Guard Wall Thickness - Area A

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20100

0.15

0.14

0.13

0.12

Xbar and R Chart

Subgr

Me

an

Mean=0.1333

UCL=0.1490

LCL=0.1175

0.06

0.04

0.02

0.00

Ra

nge

R=0.02726

UCL=0.05764

LCL=0

20100

Last 20 Subgroups0.155

0.140

0.125

0.110

Subgroup Number

Va

lue

s

0.20.1


III

III

IISpecifications

Within

Overall

0.1500.1250.100

Normal Prob Plot

0.1500.1250.100


WithinStDev:Cp:Cpk:

0.01171991.420.95


0.01205511.380.92

LEC Finger Guard Wall Thickness - Area B

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20100

0.16

0.15

0.14

0.13

Xbar and R Chart

Subgr

Me

an

1

Mean=0.1436

UCL=0.1593

LCL=0.1279

0.06

0.04

0.02

0.00

Ra

nge

R=0.02719

UCL=0.05749

LCL=0

20100

Last 20 Subgroups0.18

0.16

0.14

0.12

Subgroup Number

Va

lue

s

0.20.1


III

III

IISpecifications

Within

Overall

0.1700.1450.120

Normal Prob Plot

0.1700.1450.120


WithinStDev:Cp:Cpk:

0.01168981.431.24


0.01224941.361.19

LEC Finger Guard Wall Thickness - Area C

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APPLICATION FORMSAPPLICATION FORMS1.1. RCA:RCA:

OPAQAFL/ IRAA / TAA/ TPMA/ TPMAF/ OPAQAFL/ IRAA / TAA/ TPMA/ TPMAF/ OBACDSOBACDS

2.2. SDA :SDA : MMA/ GSIC /GWSC /PC MMA/ GSIC /GWSC /PC /CA/FMEA/ 5S Program/ Cause and Effect /CA/FMEA/ 5S Program/ Cause and Effect Diagram / CI/ ITC/ Diagram / CI/ ITC/ CA/VSRC/CTTIC/VSRCCA/VSRC/CTTIC/VSRC

3.3. RCA:RCA: TPMA/TPMAF/OBACDSTPMA/TPMAF/OBACDS

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TEAM EVALUATIONTEAM EVALUATION

Quality of the weekly postings has been Quality of the weekly postings has been improved.improved.

On-line meetings took more organizedOn-line meetings took more organized approach with the beginning of approach with the beginning of phase 2. phase 2. Timeliness was not improved due to various Timeliness was not improved due to various

reasons.reasons. Good team approach and team work.Good team approach and team work.

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TEAM’S CURRENT TEAM’S CURRENT GOALSGOALS

Apply the suggested and developed ideas with Apply the suggested and developed ideas with appropriate techniques to the Current appropriate techniques to the Current Operations in the manufacturing process.Operations in the manufacturing process.

To complete the phase 2 as best as possible.To complete the phase 2 as best as possible. Once Completed, Publish the Project in a Once Completed, Publish the Project in a

Recognized Academic or Professional Journal.Recognized Academic or Professional Journal. ( in this regard already arranged the necessary ( in this regard already arranged the necessary

steps) steps) To Obtain a “ A” Grade for the TECH 626.To Obtain a “ A” Grade for the TECH 626.

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The EndThe End

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We, 2001 (spring) TECH We, 2001 (spring) TECH 626 team, take this 626 team, take this

opportunity to thank opportunity to thank Dr. J .W. SinnDr. J .W. Sinn

for his guidance, for his guidance, encouragement, encouragement,

numerous helps, and numerous helps, and flexibility we have been flexibility we have been

receiving since the receiving since the beginning of this coursebeginning of this course..

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Thank Thank YouYou

Please see the attached phase 2 Please see the attached phase 2 file file

(final draft) for more details.(final draft) for more details.

Documents

1 BOWLING GREEN STATE UNIVERSITY College of Technology TECH 626 (Spring 2001)