Method Improvement – Helping Increase Productivity Method Improvements / Ergonomic Analysis for Engine Fuel Control Texas Center for Applied Technology Method Improvement – Helping

Lean Method Improvements / Ergonomic Analysis for

Engine Fuel ControlTexas Center for Applied Technology

Method Improvement – Helping Increase Productivity

Esau Perez, BSIE Harry Whiting, MSIE, EITVictoria C. Torres, BSIE

Thomas Sandoval, BSIE, EITJohn Smith, BSIE, EIT Prasant Chhotu, MSIE

Dr. Jerome Congleton, P.E.L.C. Escamilla

Methods and Standards BranchIndustrial Safety Coordinated with Eduardo PerezIndustrial Hygiene Coordinated with John Secrest

March 10, 2004

Texas Engineering Experiment Station

Method Improvements & Ergonomics

Texas Center for Applied Technology

• Standards are the first step in Method Improvements

• Study of work to prevent and control injury and illness

• Improve productivity, quality, customer service, marketing, delivery and reducing costs



Texas Engineering Experiment Station3 - TEES/CCAD Proprietary Information

Regulatory Emphasis!

• American with Disabilities Act (1990)• NIOSH Lifting Guidelines (1994) • Policy Outlining Army’s Roles and Responsibilities Establishing an Ergonomics Program (18 May 1998)• DoD Instruction 6055.1 – DoD Safety and Occupational Health (SOH) Program (19 August 1998)• DA PAMP 40-21 – Ergonomic Program (15 May 2000)• OSHA Ergonomic Guidelines (2002)



Millions of Dollars Lost

- Decreased Productivity - Medical Costs - FECA

- Greater than $ 6 millions (CCAD)- Due to Ergonomic Issues

- 774 days limited duty- 300 lost work days

- Production Errors

Why Operation Improvements?

IncreasedProductivity

Improved Work MethodsIncreased Efficiency

Better Tools

Less Stress & FatigueFewer ErrorsLess ReworkReduce Cost



Lean ThinkingLean ThinkingSafetySafety

Quality IssuesQuality IssuesMethods & StandardsMethods & Standards

Areas For Improvement



Time Study Methods

• Analyze and study historical data, work methods, shop layout, equipment and supplies

• Set up appointment to conduct study

• Set up video camera and start filming

• Review film, develop standard, and input to standard database

• Review with shop management for approval



Introduction

• Analyst performed CAT 2 Time Studies in the Engine Fuel Control Shop• CAT 2 – Single cycle time study• CAT 1 – Multiple cycle time study

• Lean manufacturing principles are part of our analysis.

• We are coordinating with Production, Quality, Safety and the Industrial Hygiene to provide a detailed evaluation of Engine Fuel Control processes.

• This is a summary of production/ergonomic issues which cause concern and/or delay in the Engine Fuel Control Shop

• Identify activities that might lead to injuries/illnesses on theworker



Introduction (cont’d)

• The shop mission is to disassemble, clean, inspect, overhaul, assemble and test.

• Engine Fuel Control Shop divided into three main areas:• Main Shop Area (2nd Floor)• Test Room (1st Floor)• Engine History Recorder & ECU Room (1st Floor)

• Some of the components in the area:• Hydro Mechanical Units (HMU)

• Hamilton Standard• Woodward

• Anti-Ice Valves• A&I Garret Valves• Older Model A&I Valves

• Particle Separators/Blowers• Fuel Injectors• Other Small T-700 Engine components



Lean Method Improvements / Ergonomic Analysis

• Operation: Dssy/Rpr/Assy T-700 HMU - Woodward• Issue: Fixture used to hold

HMU is not height adjustable• Detailed work • Bend over to look

inside HMU • Constrained by limited

movement of fixture• Eye/Hand/Neck fatigue• Poor posture while

sitting and standing• No leg room• Slouching




• Lean Recommendation:• Mount fixture on height

adjustable table • Anti-fatigue mats• Proper Chairs• Foot rest

• Benefits:• Reduce lower back problems• Increase productivity 0.5 ~ 1.0%




• Operation: Repetitive Motion• Issue: Use of repetitive motion

to assemble and disassemble• Many screws and/or bolts

present• Ratchets, wrenches and

screwdrivers used • Time consuming

• Lean Recommendation : • Battery-operated screwdriver

with interchangeable bits• Benefits:

• Reduced repetitive trauma disorders

• Increase productivity: 2.0 ~ 2.5%




• Operation: Repetitive Motions• Issue: Use of repetitive

motions to assemble and disassemble• Many screws and/or bolts • Ratchets, wrenches and

screwdrivers used • Time consuming

• Lean Recommendation:• Battery-operated screwdriver

with interchangeable bits• Mount wooden fixture

• Benefits:• Faster • Safer• Reduced repetitive trauma

disorders• Production increase of 2 - 3%




Solution: Examples of Battery-operated screwdrivers




• Common Use Tools:• Issue: Not enough tools

• One tool available• Hard to track tool• Wasted time looking for tool

• Lean Recommendation:• Implement a shadow board• Sign-out sheet• Place name tags inside

cubby-holes• Get more common use tools

(e.g. ohm-meter)• Benefits:

• Tool accountability• Increase productivity: 2 ~

3%NON-VALUE

ADDING ACTIVITIES!







• Operation: ALL• Issue: Lack of Proper

Ergonomic Chairs• Hard to adjust

height• Uncomfortable• Leaning to front

• Lean Recommendation:• Purchase

Ergonomic Chairs with Abdomen support




Ergonomic Chairs

• Benefits:• Stable• Fully adjustable• Comfortable• Provides lumbar

support• Reliable• Increase

productivity: 0.25 ~ 0.50%




• Operation: Cleaning Booth• Issue: Strain on shoulders and

back from holding arms out• Prolonged time• Arms reaching out inside gloves• Tiring• Unsupported arms

• Lean Recommendation:• Tool balancer with cuffs

• Benefits:• Support arms• Sustain position for longer

period of time• Comfortable• Relieves strain on shoulders




• Operation: Cleaning Booth• Issue: Insufficient light at the

cleaning booth• Causes eye strain• Increase probability of mistakes• Take part out to check progress• Reading 13.2 FC

• Required 75 – 150 FC

• Lean Recommendation :

• Mount flexible fire-proof lamp inside

• Benefits:• Track progress • Reduces eye strain • Eliminates handlings• Reduces inspection time• Reduces mistakes and rework• Increase productivity: 1.0 ~ 1.5%




• Operation: Dssy/Rpr/Assy HMU• Issue: Insufficient light at the

workstation• Causes eye strain• Increase mistakes• Hard to see work inside part• Lamp gets in the way - bulky

• Lean Recommendation :• Head gear light • Less bulky light

• Benefits:• Frees up hands• Relieves eye strain • Reduces probability of mistakes and

rework• Increase productivity: 0.25 ~ 0.50%




Solution: Possible light sources

www.geartrade.com




• Operation: Manual Presses

• Issue: Shoulder and back strain• High force required to press• Use of body to apply forced required

to press• Strain on the shoulder and back

• Lean Recommendation :• Hydraulic Press

• Benefit:• Use machine to apply force• High forces can be achieved easily• Safer process• Minimum human effort

Woodworker.com




NON-VALUE ADDING

ACTIVITIES!• Pneumatic Press at Hydraulic

Shop

• Issue: Fuel Control mechanics used pneumatic press in hydraulic shop for some operations• Far from shop – 975 ft• Take 6 minutes to walk there• Press being used? Wait

minimum of 10 minutes• Walk back 975 ft – 6 minutes• Minimum of 22 minutes lost• Overall Increase productivity: 2

~ 3%




• Operation: Freezing Parts

• Issue: Break Chunks of Dry Ice from Container• Hard to break for older worker and

also female workers• Lid is heavy• Bad posture – bending over• Mechanic needs to walk

downstairs to get ice – 780 ft• Lean Recommendation :

• Order pre-cut dry ice blocks –nuggets or pellets

• Move dry ice container to the second floor

• Raise dry ice cooler• Benefits:

• Overall productivity increase ~ 1.0

– 1.5% Woodworker.com




Woodworker.com




• Operation: Lift & Carry Heavy Objects

• Issue: Lifting and carrying heavy objects cause back strain• Commander Policy Memo #32:

35 lb maximum lift• Note: Maximum lift changed to 50

lbs• T-55 fuel control weights 40 lbs

• Lean Recommendation :• Height adjustable cart system

• Range 1 - 4 ft• Slip sheets • Push, Pull, or Slide Approach




Issue: Heavy Lifting

• Benefit:• Reduce Potential Injury• No damage to the part• One person can perform task• 2-4% productivity increase




• Issue:• Not enough Protective Boards

for storing T-55 Fuel Pumps• Modifying boards for T-53

pumps (1 hour)• Protective Boards have been on

order• Heavy objects should not be

placed over shoulder height

• Lean Recommendations:• Make more protective boards• Move heavy objects to power

zone

• Benefits:• Pumps are protected• Avoid back and shoulder

injuries/illnesses• Increase productivity: 0.25 ~

0.50%




• Operation: Shimming• Issues: Mechanics spend too

much time shimming• Tedious work• Possibility of injury while

slicing shims• Possibility of mistakes

• Lean Recommendation :• Pre-Measured color-coded

shims• Benefits:

• Safer – reduce possibility of wrist injuries or lacerations

• Accurate• Increase productivity: 1.5 ~

2.0%




Operation: Shimming




• EHR Test Stands:• Issues:

• Top chamber out of reach• Steps needed for female workers• Continuous up/down the steps

• Lean Recommendation:• Wireless keyboard • Keyboard on top rail on steps

• Separate number key pad

• Benefits:• Avoid possible injury from falling

from steps• Easier access for all (no

reaching)• Increase productivity: 2 ~ 3%




EHR Test Stands:

Number Key Pad

Wireless Keyboard




• EHR Repair

• Issues:• Many wires• Hard to maneuver wires and

soldering iron• Strain in the eyes

• Lead solder• Lean Recommendation:

• Purchase a “helping hand”• Create a jig to hold components• Replace lead solder

• Benefits:• Faster and accurate soldering• Less rework• Reduce strain in the eyes• Increase productivity: 0.5 ~ 0.75%




EHR Repair Solutions:

• Holds the wires to be soldered• Magnifies work area



Estimated Costs for Main Room Equipment

Equipment for Main Room Qty Unit Cost Total Cost

HMU Fixture w/ Vertical Adjustment 6 $ 50 $ 300

Anti-Fatigue Mat 15 $ 75 $ 1,125

Foot Rest 20 $ 35 $ 700

Battery Operated Screwdriver 10 $ 20 $ 200

Color-coded shims 15 $ 40 $ 600

Special Tool Tracking System (tags) 30 $ 1 $ 30

Ergonomic Chair 25 $ 300 $ 7,500

Tool Balancer with Cuffs 1 $ 300 $ 300

Lamp for Cleaning Booth 1 $ 100 $ 100

Workstation Optical Lights 10 $ 50 $ 500

Polishing Wheel Guard 1 $ 104 $ 104

Hydraulic Press 1 $1,500 $ 1,500

Extra Dry Ice Box 1 $ 250 $ 250

"Hot Part" Warning Labels 5 $ 10 $ 50

Height Adjustable Carts 5 $1,300 $ 6,500

Fuel Pump Board 10 $ 30 $ 300

TOTAL $ 20,058



Estimated Costs for Test & EHR/ECU Rooms

Equipment for Test room Qty Unit Cost Total Cost

Battery Operated Screwdriver 4 $ 20 $ 80

Fixture for Fuel Control 2 $ 50 $ 100

Color-coded shims 15 $ 40 $ 600

Anti-Fatigue Mat 10 $ 75 $ 750

Ear Muffs 10 $ 23 $ 232

TOTAL $ 1,761

Equipment for EHR/ECU Qty Unit Cost Total Cost

Wireless Keyboard 2 $ 85 $ 170

21-key Number Pad 2 $ 110 $ 220

Mounted Light 2 $ 100 $ 200

Soldering "Helping Hand" 5 $ 10 $ 50

TOTAL $ 640



Estimated Time Benefit - Solutions

Range

Equipment for Main Room Lower Higher

HMU Fixture w/ Vertical Adjustment

Anti-Fatigue Mat

Foot Rest

Battery Operated Screwdriver 2.00% 2.50%

Color-coded shims 1.50% 2.00%

Special Tool Tracking System (tags) 2.00% 3.00%

Ergonomic Chair 0.25% 0.50%

Tool Balancer with Cuffs

Lamp for Cleaning Booth1.00% 1.50%

Workstation Optical Lights 0.25% 0.50%

Polishing Wheel Guard

Hydraulic Press 2.00% 3.00%

Extra Dry Ice Box 1.00% 1.50%

"Hot Part" Warning Labels

Height Adjustable Carts 2.00% 4.00%

Fuel Pump Board 0.25% 0.50%

TOTAL 12.75% 20.00%

0.50% 1.00%

3.75%2.50%TOTAL

Ear Muffs0.50%0.25%

Anti-Fatigue Mat

2.00%1.50%Color-coded shims

Fixture for Fuel Control1.25%0.75%

Battery Operated Screwdriver

HigherLowerEquipment for Test Room

Range

5.50%3.75%TOTAL

0.50%0.25%Soldering "Helping Hand"

2.00%1.50%Mounted Light

21-key Number Pad3.00%2.00%

Wireless Keyboard

HigherLowerEquipment for EHR/ECU

Range



Overall Summary

• Total Cost consists of equipment used for all components documented on at Engine Fuel Control Shop• Equipment Cost - $22,460 • Combined Increase Productivity: 19.0 ~ 29.25%

Range

Description Total Cost Lower Higher

Equipment for Main Room $ 20,058 12.75% 20.00%

Equipment for Test room $ 1,761 2.50% 3.75%

Equipment for EHR/ECU $ 640 3.75% 5.50%

Overall Total $ 22,460 19.00% 29.25%



Return on Investment -ROI Analysis

• ROI based only on operations performed on two components • EAF – Hamilton Standard Fuel Control (GE T-701C – AH-64) • B1G – Woodward Fuel Control (GE T-700 Engine Family)

• Studied operations included disassembly, cleaning, inspection, assembly and testing

• For EAF & B1G Operations Only:• Equipment Cost: $21,366• Increase Productivity: 15 ~ 23.25%

• Total Savings excluding tool investment: $ 3,127 per unit

What is the Return??

TOOL COST

Hours Cost/Hour TotalEstimated

Standard Hours Prior to Study 63.75 84.44$ 5,383$

Standard Hours after Study 87.64 84.44$ 7,400$

Benefit 2,017$

Estimated Time Benefits

Estimated Standard Time

after Implementation Total Cost

Savings (Excluding the Implementation

costs)Implementation

Costs

Total savings from Time Study

and MIImplementing

Method Improvements 15.0% 74.49 6,290$ 1,110$ 21,366$ 3,127$



Return on Investment -ROI Analysis

• Combined 360 units/year for EAF & B1G – 180 units each

• Combined of 30 units/month

• Return on Investment is after 21st Fuel Control!!!!! – Less than 1 month!!!!

Number of Units Net Cash Flow Cumulative0 (64,166)$ (64,166)$ 1 3,127$ (61,039)$ 2 3,127$ (57,911)$ 3 3,127$ (54,784)$ 4 3,127$ (51,656)$ 5 3,127$ (48,529)$ 6 3,127$ (45,401)$ 7 3,127$ (42,274)$ 8 3,127$ (39,147)$ 9 3,127$ (36,019)$

10 3,127$ (32,892)$ 11 3,127$ (29,764)$ 12 3,127$ (26,637)$ 13 3,127$ (23,510)$ 14 3,127$ (20,382)$ 15 3,127$ (17,255)$ 16 3,127$ (14,127)$ 17 3,127$ (11,000)$ 18 3,127$ (7,872)$ 19 3,127$ (4,745)$ 20 3,127$ (1,618)$ 21 3,127$ 1,510$ 22 3,127$ 4,637$ 23 3,127$ 7,765$ 24 3,127$ 10,892$ 25 3,127$ 14,019$

With MI



Potential Savings

Monthly Production Run Savings

Total Monthly Savings

Investment (Equipment &

Analyst) Annual30 3,127$ 93,823$ (64,166)$ 1,061,704$

Combined Fuel Control

$1.06 Million First Year Potential Annual Saving

• Assuming 10 year tool-life expectancy

$ 11 MillionPotential Saving over 10 Year Period

YearBenefit per

Year Investment Annual Net Benefit1 $1,125,870 ($64,166) $1,061,7042 $1,125,870 $0 $1,125,8703 $1,125,870 $0 $1,125,8704 $1,125,870 $0 $1,125,8705 $1,125,870 $0 $1,125,8706 $1,125,870 $0 $1,125,8707 $1,125,870 $0 $1,125,8708 $1,125,870 $0 $1,125,8709 $1,125,870 $0 $1,125,87010 $1,125,870 $0 $1,125,870

TOTAL $11,194,535

Fuel Control

• Based on our previous experience similar results should be expected from other components within the shop

Intangible Benefits• Decrease in FECA claims• Reduction in lost work days and restricted days• Worker’s Health and Safety• Increase morale• Increased quality



Potential Savings from Previous Contracts

Work Center Title Time SavingsEquipment

Cost Payback Period SavingsTime of Savings

Savings/ Cost

5UDE0, 5UEE0, 5UEF0

UH-60 Electrical Repair 30% - 42% 18,573.66$ 6 months $300,000.00 1 yr 17.5

5SAA0 Blade Shop 27% - 44% 7,581.00$ 2 weeks $2,910,000.00 1 yr 1.85TDJ0 Rotor Head 18% - 40% 45,200.00$ 9 weeks $313,179.00 1 yr 16.8

5TDB0Transmission

Shop 28.5% - 44% 25,170.00$ 3-4 months $314,679.00 1 yr 16.75UBA0 5UBB0 5UBD0 5UBE0

UH-60 Assebly line (AMG Trade) 27.1% - 38.2% 158,622.00$ 2-6 months $1,327,000.00 1 yr 4.0

5UBA0 5UBB0 5UBD0 5UBE0

UH-60 Assembly line (Electical,

Sheetmetal and Avionics Trades) 1.60% 8,784.00$ 2-6 months $86,400.00 1 yr 60.8

5TBF0* Engine Paint 14.4% - 31.4% 3,070.00$

5TDB0*Transmission

Dissy. 14.3% - 24% 2,919.74$ 5TBA0* Plating Shop 20.7% - 26.4% 8,284.90$ 5UFE0* Upholstery Shop 33% - 62% 31,026.30$

Total 309,232$ $5,251,258 Average 19.58

ROI ANALYSIS



Potential Savings with 12,500 CAT II Standard Hours Developed

• Linear Relationship• Factor multiplied by 5 (2,500 to 12,500 CAT II Hours)• Assumed same factor for total equipment cost and total potential

savings

Shops Covered Time Savings Equipment Cost SavingsRange 1.6% - 62% $2,919 - $158,622 $86,400 - $2,910,000

Average 29.7% 32,295$ 990,252$ Total 309,232$ 5,251,258$

Shops Covered Time Savings Equipment Cost Savings50 29.7% 1,546,158$ 26,256,290$

2,500 CAT II Hours Developed

Linear Relationship with 12,500 CAT II Hours Developed

10



Contract Vehicles

• Aging Aircraft Commands:• U.S. Army Aviation Missile Command Omnibus 2000 (O2K)• U.S. Air Force Design and Engineering Support Program (DESP)• U.S. Navy Technology Investment Agreement (TIA)

• Other Commands:• U.S. Army Simulation, Training and Instrumentation Command

Omnibus• U.S. Army Medical Research Materiel Command CAAS Contract• U.S. Air Force 311th Human Systems Wing Basic Ordering Agreement

• Other Avenues:• Grants• Broad Agency Announcement (BAA)• Program Research & Development Announcements (PRDA)• Cooperative Research & Development Agreement (CRDA)• Cooperative Agreements (CA)• Texas Qualified Information Systems Vendor (QISV)



FOR MORE INFO

Dr. John F. Ayala, P.E.210-534-7227

[email protected]

Method Improvement – Helping Increase Productivity Method Improvements / Ergonomic Analysis for Engine Fuel Control Texas Center for Applied Technology Method Improvement – Helping

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