Multidisciplinary Engineering Senior Design Project PO6208 – ArcWorks Closure Tube Assembly Adaptation Preliminary Design Review 02/24/2006 Project Sponsor: ARC Works of Monroe County Team Members: Team Leader George Gooch, Bill Lucas, Chris Donati, Drew Stone- Briggs, Hui Kim, Mike Hayden, Mike Levis, Jeff Coppola Team Mentor: Dr. DeBartolo (ME) and Dr. Marshall (IE) Acknowledgements: This material is based upon work supported by the National Science Foundation under Award No. BES-0527358. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation.
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Team Members:Team Leader George Gooch, Bill Lucas, Chris Donati, Drew Stone-
Briggs, Hui Kim, Mike Hayden, Mike Levis, Jeff Coppola
Team Mentor:
Dr. DeBartolo (ME) and Dr. Marshall (IE)
Acknowledgements:This material is based upon work supported by the National Science Foundation under
Award No. BES-0527358.Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science
Foundation.
Presentation Overview Sponsor
Who they are What is their current process
Team Goals How are we going to help ArcWorks Needs, Feasibility, and Concepts
Final Concept What improvements are being made Time, Flow, Material Handling
SD II
ArcWorks
ArcWorks is the vocational division of the Arc of Monroe County
Have been serving individuals with developmental disabilities and their families for over forty years.
Specialize in providing subcontracting manufacturing services
Comprised of over 250 assembly operators
ArcWorks – Closure Tube Assembly (CTA) A process that supports the assembly of a
bent stem closure with a tube attachment
Quantities produced are close to 500,000 units per year
Currently there are 3 process steps The team is dealing primarily with steps 2 and 3
CTA - Components
Finished Closure
Components
Closure (Various Sizes) Adapter Tube
(Various Lengths)
Step 1 – Straw Cutting Process Machine
10 tubes at once are inserted into the top of the automated tube cutter. The machine cycles, cuts the tubes and they drop through into a box.
CTA - Step 2 (Closure/Adaptor Sub-Assembly) Process MachinesClosures are placed in the bottom fixture and Adapters are placed in the top fixture of one of two style manual presses. The presses are cycled to create the Closure / Adapter Sub-assembly.
CTA - Step 3 (Final Assembly Press) Process Machine
Closure / Adapter Sub-Assemblies are placed in the top fixture of the automated press. Tubes are placed in the bottom fixture. The machine is cycled to create the final assembly.
Team’s Task
Lean Development – integration of sub assembly production orders/releases to ensure minimum/maximum quantities are on hand and flow as required (SD I)
Production Process – improvement of the assembly process, changeover & set-up, ergonomics/safety, and improvement of operator productivity (SD I)
Purchasing Function – ordering of the raw tubing that is cut to length for finished goods assembly (SD II)
Inventory Management – of both raw and cut tubing (SD II)
Needs Assessment
Tools Used
Problem Scope/Definition The mission of this design project team, PO6208, is to redesign a
process that supports the assembly of a bent stem closure with tube attachment called the Closure Tube Assembly. In this design the team hopes to improve the process flow, daily production and worker safety/comfort.
Objective Trees
5 Why’s
Needs Assessment - Outcome
It was decided through evaluations that this machined needed to: Combine assembly steps Decrease the number of moving parts Limit complexity of design Create fixtures that can be used for all product
sizes Use standard components Improve ergonomics Add counters
Feasibility Assessment
Tools Used
REST Resource, Economics, Schedule, Technical
Pugh Method Un-weighted, all attributes equally important
Weighted Comparison Method Looks at attribute importance
REST Method
Compares the chance of success of each idea Rating Scale
Eliminates repeated manual motion Reduces ranges of motion Common plane of motion
Safety Anti-tie-down buttons E-stop
SD II - plans
Investigate Warehouse/Inventory Issues Re-order Points Safety Stock Flow of Material
Desired Outcomes – Manufacturing Area Increased productivity by the ArcWorks team Fewer rejects Higher satisfaction of workers Layout Redesign
Economic Order Quantity -EOQ
Defines the optimal quantity to order that minimizes total variable costs required to order and hold inventory. Q * = optimal order quantity C = cost per order event (not per unit) R = monthly demand of the product P = purchase cost per unit F = holding cost factor; the factor of the purchase cost that is
used as the holding cost (this is usually set at 10-15%, though circumstances can require any setting from 0 to 1)