Detailed Design ReviewNathan Arrowsmith, Samantha Reinhart, Rachel Short, Yelena

Tuzikova

Supplier Kitting Idea“Top 16 BOMs”

Current Kitting Observations:Purpose / Benefits: -Cell associate kits jobs a few days ahead of time which allows her to know if she has enough parts for the job-Helps her know which jobs to work on-Reduces assembly time: all parts are directly at POU (time study still needs to be completed)

Observations:-Takes 2-5 minutes to kit each job (this work could be redistributed in future)-Not in standard work-Cell associate currently works on orders in order dependent on: if she has parts and if the machine is already set up

General Material Presentation Rules and How They Can Be Applied to 922A

“What good looks like”

1. Parts are oriented so that a quick visual estimate of the quantity can be made.

a. Flanges, dials and other cylindrical parts are kept upright.

b. Parts with large kanban size and small unit volume are subdivided.

2. Parts are easy to replenish and retrieve during assembly.

a. Rods are stored in tubes with enough space around them to not get tangled.

b. Tools are not blocking view of parts. They can have dedicated storage inside the bin or go to an existing flexible tool storage.

Material Presentation Rules Continued

3. Parts are in containers of appropriate size and color.

a. Color: Electronics in black bins. VMI items in another color (green?). Remaining fabricated and purchased items in yellow or white bins

b. Size: No oversize bins blocking view of other bins. No bins overflowing with parts.

4. Width of each machine station and assembly area is minimized.

a. Plan for enough room to store one days worth of corrugated.

b. Vertical storage is utilized where available.

Material Presentation Rules Continued

5. All dedicated storage is clearly defined

a. Dedicated storage for overstock and repack floor space in aisle 2

6. All flexible storage is clearly defined

a. Overstock fabricated parts

7. Visual information is clearly visible.

a. Part number for all locations

b. Minimum and maximum quantities for non-kanban fabricated part locations

c. Kanban part locations have either a kanban card or a purple laminated card indicating the item is on order

Future State Ideas Aisle 1:● Arrange by machine is most effective - have Kanban quantity at

POU● Utilize unused vertical space better throughout

Aisle 2:● Have overstock with Kanban cards● Organize “Swedish” station by part number with the exclusion of

heavy and large bins which are kept at bench level or underneath.o Cell associate wants bins organized by frequency with

infrequently used parts higher up on the rack. This setup is highly problematic for the W.S.

● Two out of four rows of the “Swedish” parts rack are unused● Moving of repack operation?

Tests/Experiments

1. Tape test

2. Self-reporting

3. Alphanumeric ordering in Aisle 2 (bench 8)

4. Normal vs Abnormal ideas

Tape Test

Test: Taped off areas identified in Aisle 2 as under-utilized in our last review. Review on visits and ask Jen if tape has been breached.

Status: Preliminary results - Repack area rarely utilized in full. Usually only half-utilized. Areas adjacent to overflow/kit racks very under-utilized.

Tape Test Pictures & Conclusions

Conclusion: We should evaluate the efficacy of merging the repack task in this cell with another function.

Alphanumeric Bin Organizing

Test: Compared time to locate materials on a BOM in the kitting/over stock area with the pre-existing bin locations vs. an alphanumeric arrangement.

Status: Confirmed that alphanumeric arrangement takes less than half the time. Some apprehension with cell associate. Awaiting feedback after use.

Self ReportingTest: Have cell associate log material activities that require leaving the cell or that negatively affect production.

Status: On-going- will be extending to water spider.

Observations: -Spends time getting shared components from other cells (few times a week, about ten minutes each time)-Spends time getting VMI parts from outside cell (few times a week, about two minutes each time)-Leaves cell to get boxes and labels frequently

Normal vs. AbnormalAre the following normal or abnormal?

● Cell Associate regularly leaves cell to retrieve component parts.

● Cell Associate kits own parts.

● Cell Associate adjusts production schedule due to missing parts.

● Infrequently used parts are stored in large quantities.

● Space is almost always utilized completely.

Project Plan

Preliminary MSD II (Fall) Plan:

• Assess and complete implementation

• Review audit sheet

• Determine which cells our rules could work in: design for exceptions

• Tape (space) test for other cells

-Goal: justify space savings and potentially combine extra space

-Extra space used for more central storage (kitting?)