assembly fixture inventory report presentation
TRANSCRIPT
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Excellence in Execution
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Project : Assembly Fixture control and conventional naming Team Leader: Valeria Cabriales
Team Members:Carlos Aragon.Adrian Sanchez de la CerdaSergio Torres Alvarado
Managers:John Tufts - MSS-CA PLMRamiro Baez – Technology Manager
Quality: Omar Sangabriel – QMS CoordinatorEsau Garcia - Quality Plan Control EngineerAngel Ramón Medellin López
Finance Controller : Lupita Jesus
LSS Support : Juan Angel Lopez Franco
Project finish date :
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Personal Introduction
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Valeria Marisol Cabriales Garza.
Mechatronic engineer student at,Facultad de Ingeniería Mecánica y Eléctrica (UANL)
Academic experience: Academical exchange: Dresden, Germany (July 2014- July 2015).
Professional experience:OSRAM Regensburg Germany (January 2014- July 2014)Optosemiconductors industry
LabView programmer Intern (testing and projects development).
Preh de México (August 2014-December 2014)Plastic injection for automobile industryMaintenance Intern.
Schlumberger CMPU (January 2015 – actual )Completions accessories Manufacturing Intern, Multistage.
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Project Background An assembly fixture is a tool to perform an acceptance test. There are many different types and designs. They can be stated on GEMs.
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Project BackgroundCribmaster is an inventory database.
Kits (relation between the part number and its corresponding fixtures)
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Project Background 1,577 folders of fixtures drawings on the local server, “PJF####”. Fixtures for machining and assembly are mixed in the same server file.
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DefinitionD
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Business Objectives:― On Time Shipment― HSE ― Quality
KPIs to measure impact:― OTS― Fixture Inventory
SCOPE: ― Assembly
MMS-CA
HSE
Quality
On time shipment
Inventory
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Process Map of a fixtureD
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Customer Demand
Part Number
ME’s
Planning
Search inventory of fixture
New Fixture design Production Quality
Assembly and
functional test
Pressure test
Assembly
Next Operation…
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Problem /Opportunity Fixture’s nomenclature and control process are not standardize. It is not stated which fixture to use for a particular assembly
therefore time wasted during the search of fixtures. Non unified process between SC, MSS and LH Duplicated fixtures on inventory. Lack of fixture at the moment of the acceptance test
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Measure – Process Map
Adexa Assembly demand
Design or buy
new fixture
Perform the
acceptance test
In-house or vendor fabrication
Process map before Project implementation.
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Planning
EM’sYES
NO
YES
Does a Fixture is required?
Fixture on
GEMS?Cribmaster
NOSearch
adequate fixture
NO
No action required
YES
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Measure – Process Map
Adexa Assembly demand
Design or buy
new fixture
Perform the
acceptance test
In-house or vendor fabrication
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Planning
EM’sYES
NO
YES
Does a Fixture is required?
Fixture on
GEMS?
Search on Cribmaster Inventory
NOSearch
adequate fixture
NO
No action required
YES
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Measure - Quantity of Fixtures per type
Drift Bar (OD /ID)
26%
Rod Bar2%
Test Sleeve3%
Test plug24%
Test cap15%
Bore seal18%
Expander (hp body)
1%
Landing Nipple 6%
Spacer4% Nut
1%
Drift Bar (OD /ID)Rod BarTest SleeveTest plugTest capBore sealExpander (hp body) Landing Nipple SpacerNut
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Types of fixtures
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Analyze
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Lack of fixtures at
the moment of
the test.
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Analyze
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Problems/Root Causes SolutionNo ownership of fixtures assignation process.
Implementation for assembly fixture control procedureIndividual method to assign fixtures
No standardized procedure to register fixture on data base
No accurate information that describe the fixture
No restrictions for duplicated fixture
Fixture inventory reportTime wasted while searching the corresponding fixture
Inventory status is not complete reliableFixtures failure Validation of fixtures
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Improve
New Assembly and test fixtures control procedure DMS#101895158.
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RELEASED
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Improve - Procedure content
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Assembly fixtures
Funcitonal test
Landing Nipple
Pressure test
Test plug/cap
Test cap (premium thread)
Test plug A
Test plug B
Bore seal plug A
Bore seal plug B
Rod bar Nut HP body (expander) Test sleeve
Drift test
Drift bar
OD Drift bar (external diameter)
ID Drift bar (Internal
diameter)
Fixture categorization.
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Improve - Procedure content
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Fixture example nomenclature.
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Improve
Example of a faster search:
Thread type : 1.750-4 stub acme
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Improve – Assembly fixtures process map
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- Define if a fixture is required- Search adequate Fixture
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Improve – Assembly fixtures process map
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- Compatible fixture or new design- Sustaining validation
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Improve – Assembly fixtures process map
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- Add fixture information to cribmaster
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Improve – Assembly fixtures process map
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- Verify fixture inspection
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Improve – Assembly fixtures process map
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- Purchase or machine a fixture
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Improve
Standard work instructions (SWI) :―Register a new fixture in cribmaster (AT-49).―Register a kit of fixtures in cribmaster (AT-50).
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AT-49 AT-50RELEASED
RELEASED
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Excellence in Execution
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Improve
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Excellence in Execution
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Improve
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Excellence in Execution
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Improve
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Excellence in Execution
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Improve
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Excellence in Execution
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Improve
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Excellence in Execution
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Improve
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Actual status of fixtures on cribmaster
Drift Bar (OD /ID)
26%
Rod Bar2%
Test Sleeve3%
Test plug24%
Test cap15%
Bore seal18%
Expander (hp body)
1%
Landing Nipple 6%
Spacer4% Nut
1%
Drift Bar (OD /ID)
Rod Bar
Test Sleeve
Test plug
Test cap
Bore seal
Expander (hp body)
Landing Nipple
Spacer
NutI
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Control
Assembly and Test Fixture Control procedure Standard work instructions Assembly fixture report Meeting and indoctrination sessions
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Project CostsCost and benefits calculations
Project: "Assembly Fixtures control and conventional naming"
Savings calculations (time saving)
Time searching (before)Time searching (after
improvement)New kits registered on
2015 Fixtures average per kit ME's hour cost Subtotal saving
1:00:00 0:10:00 81 2 $ 22.50 $ 2,187.00
Cost calculations
Hours Hour cost Subtotal cost
40 22.5 $ 900.00
Total calculations
Subtotal saving (time searching) Total project cost TOTAL
$ 2,187.00 $ 900.00 $ 1,287.00
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Project Benefits:
― Faster search of fixtures― Avoid any extra inventory ― Accurate information about fixture characteristics ― Planning activities are done before production dates ― Improve 16% of lack of fixture― Improve 66% fixture process flow for CA― Creation of 92 kits until today.― Could be used by the 3 PL.
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Next Steps
― Continuous improvement of the inventory report― Migrate fixtures to Gems― Reduce the variety of fixture designs
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Knowledge gained…– Drawings interpretation.– SWI, visual aid, process map, procedures development. – Machining, testing and Assembly process– Time management– CI projects development
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Question and answer section
?
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Thank you!
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Measure Total number of kits of MSS part numbers until 2014: 233 kit’s Average per year: 38 kitsM
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55 53
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Number of Kits per yearNumber of Kits per year
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Definition Catalog of fixtures has very varied options.
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Test plug B Test plug BRod Bar
Test plug B
Bore seal plug B
NutSpacer
Test plug B Bore Seal plug B
Test plug B Configuration
Mixed Bore Seal Plug B/Test Plug B configuration
Bore Seal Plug B configurationBore Seal plug BBore Seal plug B
Rod Bar
SpacerNut Nut
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Project BackgroundThe (F.A.T.) factory acceptance test:- Drift test - Functional test - Pressure test
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