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 ● 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. ○
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 ● out - 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?
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