Multidisciplinary Senior Design (MSD I) P18718: Detailed Design - PowerPoint PPT Presentation

Multidisciplinary Senior Design (MSD I) P18718: Detailed Design Review Nick Campagnola Matt Eisner Ryan Leeson Kyle Leung Alec Meta

Agenda Background ● Problem Statement ○ Engineering/Customer Requirements Review ○ Design Review ● Engineering Checklist ○ Test Plan Proposal ○ Projected Savings ○ Updates ● Risk Assessment Update ○ Project Plan ○ Looking Ahead (MSDII) ○ Questions ●

Background

Problem Statement Kodak is interested in some process improvement assistance with one of ● their production operations. The current process flow for Kodak 135 Film production has three key ● operations: The first is a Dial Operation, the second is a Spooler Operation, and the final is a ○ Packaging Operation. Department Management has identified that there are opportunities for ● reducing the setup times of the various processes and eliminating wastes. Any reduction in setup time or identified wastes is considered a success. ○ Any additional changes to improve the department's processes is a plus. ○ Main focus on Packaging Operation improvements. ●

Customer Requirements Review

Engineering Requirements Review

Design Review

Engineering Checklist ➔ Finished initial draft of Packaging Process Flow Charts ➔ Implementation of elimination of Blue Jacket use ➔ Created final draft of MSDII testing plans ➔ Estimated time savings of changes created based on average recorded Changeover

Test Plan Proposal Remove need for jackets during changeover [ ✔ - Complete, Projected 3% Savings] 1. 2. Color coding all plugs 3. Alignment arrows on plugs 4. Taping floor for equipment 5. Taping floor for paths 6. Raise sign string 7. Install hook/device to hold wires 8. Implement process flow chart visual tool (floater sheet) 9. New path trials 10. Arrangement of machines into order of use 11. Use carts for specific batches of materials 12. Visual Management (in general) 13. Update standard work 14. Add more ergonomic floor mats to work cells 15. Improve process for Y shaped canned feeder tube

Test Plan Proposal

Test Plan Proposal ● Budget? ● Items we may need for process changes: ○ Floor Tape ○ Paint ○ Label Maker/Printer ● How far in advance do we need to schedule a Kaizen to accommodate for production staff schedule?

Projected Savings / Visual Management Process Improvement Estimated Time Savings EHS Considerations 3P Machine Changeover Implement process flow 45 Seconds N/A chart visual tool 3P Machine Changeover 20 Seconds Setting safe location for Floor Markings for machines Packaging Machines 3P Machine Changeover 10 Seconds Prevent electrical hazards Color Coding Plugs 3P Machine Changeover Prevent electrical hazards Alignment Arrows on plugs 10 Seconds 3P Machine Changeover Tape out path for Machine 20 Seconds Prevent machines impacting people or objects

Projected Savings / Reducing Adjustment Process Improvement Estimated Time EHS Considerations Savings 3M Tape Machine Marking height and 20 Seconds Improves ergonomics width 3P Machine 30 Seconds Making sure machine is Floor Markings for Changeover in safe location for work Machine to align feeder tube 3P Machine 10 Seconds N/A Improve process for Y Changeover shaped canned feeder tube

Projected Savings / Process Improvement Process Improvement Predicted EHS Considerations Time Savings 3P Machine Changeover Adding pictures to standard work 10 Seconds N/A 3P Machine Changeover 5 Seconds Prevent machine entangling with string Raise the sign string when moving machine 3P Machine Changeover 20 Seconds Improves communication between Reduce waiting with parallel tasks workers - eliminating potential accidents 3P Machine Changeover 15 Seconds Prevent machine entangling with wire Hook / device to hold wires in place in when moving machine packaging machines Dial Operation 30 Seconds Reduced the need of walking User carts for specific batches of materials (ergonomic) 3P Machine Changeover 30 Seconds Approved by EHS manager Remove blue jackets

Updates

Risk Assessment Update Importance Likelihood Severity # Risk Risk Type Cause Effect (Likelihood Actions (1,3,9) (1,3,9) * Severity) Interact with all Kodak Leaders to ensure that they have a broad, Incident occurs and key Kodak leaders Harder to convey change and gather 13 Resource External source 1 9 9 high level understanding of the are unable to return to work participation for new ideas project in the case that a leader is not available. Ensure that material issues will not Tape issues continue to interfere with More machine downtime, less time to conflict with setups through Root 14 Technical Machine issues 3 9 27 setups see influence of changes Cause Analysis or other investigative methods by Kodak Talk with all employees early on in Less incentive to improve changeovers Change to 1 Shift 15 Societal Project is put at a lower priority 1 9 9 MSDII and ask if they have any after switching to 1 Shift schedule Schedule questions or concerns. Markings of wires are inaccurately Verify changes to wire markings before 16 Technical Human Error Changeover takes longer 3 9 27 labeled applying Revised changeover paths aren’t as 17 Technical Human Error Changeover time is not improved 3 9 27 Re-evaluate paths and re-implement effective as anticipated Cannot find time within production Busy production Work with supervisors to plan in 18 schedule to implement changes without Resource Unable to implement improvements 3 9 27 schedule advance times to make changes interrupting packaging operations Weather causes bad Unable to perform plan for the day Reschedule implementation day if 19 Snowstorms/ weather cause delays Environmental 3 9 27 storm (possible implementation day) possible

Project Plan

Project Plan

Looking Ahead (MSDII) We will be coming in SAME DAY but DIFFERENT TIME ! ● Tuesday/Thursday: 2 pm - 5 pm → 11 am to 2 pm ○ MSDII and our next and final semester starts Tuesday, January 16th ● and ends Monday, April 30th . Our plan is to conduct Quick and Efficient Kaizen events to implement our ● changes and spend more time on process change sustainability and observation.

MSDII Implementation Plan Week 1: Catch up with Customer Week 2: Discuss Kaizen Procedures/Hold Meeting with Staff Week 3: Work out concerns of staff, Survey Week 4: Kaizen 1 Week 5: Kaizen 1 Follow-up, Data Collection Week 6 : Kaizen 1 Review

Questions?