Multidisciplinary Senior Design (MSDI) P18718: Preliminary Detailed - - PowerPoint PPT Presentation

Multidisciplinary Senior Design (MSDI)

P18718: Preliminary Detailed Design Review

Nick Campagnola Matt Eisner Ryan Leeson Kyle Leung Alec Meta

Agenda

• Background

○ Problem Statement ○ Engineering/Customer Requirements Review

• Preliminary Detailed Design Review

○ Engineering Checklist ○ Change-Over Breakdown ○ 8 Wastes Identification ○ Fishbone Diagram

• Updates

○ Test Plans ○ Risk Assessment Update ○ Project Plan

• 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
• perations:

○ 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.

Engineering Requirements Review

Engineering/Customer Requirements Review

Preliminary Detailed Design Review

Engineering Checklist

• Gemba Walk
• Identified Wastes
• Created Initial Draft of Test Plan Actions
• Captured second changeover

Change-Over Breakdown

8 Wastes Identification

1. T - Transportation 2. I - Inventory 3. M - Motion 4. W - Waiting 5. O - Over Processing 6. O - Overproduction 7. D - Defects 8. S - Skills

Transportation

• Moving 3P machine not involved in change over out of path
• Moving pallets during changeover

Inventory

• Large amounts of material stored in various places in the

production area.

• Material locations don’t seem to be officially marked as

designated location.

Motion

• Operators have to travel farther than needed due to

placement of needed materials. ○ If the materials were placed closer to where they have to be used, it could reduce time spent moving to gather them.

Waiting

• Communication between Spooler and 3P operators to

ensure they are ready to receive new order.

• Waiting on mags and other necessary components for

various operations.

• Waiting on glue to heat up with the 3P Machines

Over Processing

• Observed workers doubling handling tasks such as moving

table into place during changeover. Two different people both did the same job unaware it had already been completed.

• Performing additional steps that do not add value or safety

to process (blue jackets).

Overproduction

• Production board has shown production numbers above the

needed amount. ○ Not sure if it is for compensation of previous low periods, or if production numbers are always higher than necessary.

Defects

• Film got scratched
• Machines breaking down
• Taping issue with the 3P machines
• Velvet issue in Spooler operations

Skills

• Kodak employees vs contract employees being capable of

completing changeover procedures. ○ Possibly have the non-Kodak workers do changeovers ○ Make changeover easier to do

Updates

Test Plans - Desired Outcomes

• Reduce changeover time by 15%
• Make changeover process highly visual
• Strategically place inventory in work areas
• Create floater sheets for guideline help
• Eliminate steps that do not add value or safety to the

product/ process

Test Plans

• Standardize / simplify changeover to be understood by

non-Kodak employees ○ Color coding plugs more ○ Alignment arrows on plugs ○ Taping the floor for specific placement of equipment

• Raise the sign string
• Hook / device to hold wires in place in packaging machines
• Implement process flow chart visual tool to each operation
• Interview employees on process concerns

Test Plans

• Try new path for changeover
• Arranging machines into order of use
• Have materials in a centralized location rather than spread
• ut - have a cart for materials
• More preparation before changeover occurs
• Eliminate unnecessary steps
• Visual Management
• Assist in update to standard work documents
• Run 3P changeover with parallel steps

Risk Assessment Update

Project Plan

Project Plan

Thank you!

Questions?