WIP AT MILWAUKEE GEAR

IE390: JUNIOR PROJECTSean Larson Project Team Leader

Jonathon Cerny Project Team Member

Berea Janzen Project Team Member

Ryan Lowery Project Team Member

Varun Modi Project Team Member

Agenda

Background / Problem Description

Current State and Data Collection

Initial Designs

Final Design

Implementation

Conclusions

Background

Leading producer of gears Experiencing growth Current Storage Problem with current method

Problem Description

Statement of problem Final goal Project team’s scope

Constraints

Height- 84’’ Width- 42” Movable Fit on flatbed truck Easily accessible

Agenda

Background / Problem Description

Current State and Data Collection

Initial Designs

Final Design

Implementation

Conclusions

Current State

WIP stored on pallets

Not racked/stacked

Minimal space

Data Collection

Raw material weights Pallet dimensions Part routings

Agenda

Background / Problem Description

Current State and Data Collection

Initial Designs

Final Design

Implementation

Conclusions

Initial Design: Collar System

• Made of wood• Allowed staking• Light and inexpensive• Flexibility

Initial Design: Vertical Staking

Gears staked vertically Needed to purchase

loading equipment No stacking

Initial Design: Horizontal Staking Metal Individual shelves for

each gear Can remove gears

independently No stacking Heavy

Design Selection

Cost Functionality Durability Ease of Use WeightWeight 2 4 3 1 1

Collar System 3 3 3 2 1Vertical Stacking 2 1 3 1 2Horizontal Stacking 1 2 3 2 3Current System 3 2 2 3 2

Flipping AidEase of

ProductionEase of

ImplementationCreativity Space Saving

Weight 1 1 1 1 5

Collar System 1 3 2 2 3 53Vertical Stacking 2 2 2 3 2 39Horizontal Stacking 1 1 2 2 2 40Current System 1 3 3 1 1 38

Grand Total

Agenda

Background / Problem Description

Current State and Data Collection

Initial Designs

Final Design

Implementation

Conclusions

Final Design

Features

CollapsibleNesting

Assisted Lifting

Final Design

Benefits• Space saving• Durability• Safety

Future State• More effective floor

usage• Stacked containers

Agenda

Background / Problem Description

Current State and Data Collection

Initial Designs

Final Design

Implementation

Implementation

Stage 1: PrototypeTesting

Viable solution

Stage 2: PilotOne product line

Create accountability

Stage 3: Full ImplementationOne product line

Remove old materials

Conclusions/RecommendationsConclusions Recommendations Design needs minor

changes related to cost Can be implemented

quickly Greatly increases space

for WIP

Clean house Remove unnecessary

equipment Use current racks Smooth production