1. Stefan Enjem – ISE Joe Van Hofwegen - ISE Young Lee - ISE Joe Pecht - ME Walter Freitag - ME Jason Zion - ME Luis Garcia - EE

2. Introduction Product Goals Increase QPH 4 to 6% 2 year payback Safety and Quality

3. Production Line Layout EOLT 90 Continuous Counterclockwise Loop Variable Staffing

4. Areas of Improvement Downtime End of Line Tester Leak and Snap Ring Test Process Time PCV Assembly Station Procedures Production Board Preventive Maintenance Work Flow Pallet Flow Control and Failure Response Alternative Configurations

5. Downtime Micro-stop - Downtime of less than 5 minutes # of Micro-stops/month

6. Downtime: End of Line Tester Purpose Final Station before leaving clean room Fully tests all motors Problems Downtime Micro-stops Causes Existing Technology

7. Assembly Cell Design Downtime: End of Line Tester

8. Solution Original system specs Modifications required Design New connector

9. Finite Element Analysis Benefits Reduced downtime Decreased operator interaction Increased potential motor output by 7% Downtime: End of Line Tester

10. Rubber Connectors Leak Test Problem Solution PM Downtime: Leak and Snap Ring Test (210)

11. Optical Test Problem False Failures / Glare Solution Mirror Assembly [Nerlite Doal-50-led] Station Improvement Benefits 1% increase in total motor output Downtime: Leak and Snap Ring Test (210)

12. Process Improvement Histogram shows major sources of backup

13. Process Time: PCV Assembly (90) Problems: Process time, bin layout Solution: Move part bins, Modify Program Benefits: Reduction in assembly time (5 seconds), Ergonomically designed set up BeforeAfter

14. Procedures: Preventive Maintenance Creation of a Preventive Maintenance Schedule List of tasks to be completed on a weekly basis Complete inspection of the line Benefits Increased reliability of stations Reduction in catastrophic failures Less disruption of production time Similar PM programs show a 4% improvement

15. Procedures: Visual Production Board Performance Assessment Communications Hub

16. Work Flow Improvements Pallet Flow Control Inhibiting Release Logic Failure Response Time Minimizes blocking Increases motor output EOLT 90

17. Arena Simulation Arena Model created to analyze system Mimics the behavior of the real system Interface for user created Analyze potential system changes

18. Arena Model: Background

19. Arena Model: Set-up

20. Arena Model

21. Work Flow: Alternatives Arena Model used to analyze system Optimal configurations and results Based on improvements made to the line: Optimal Pallets is 47 OperatorsSpeedPartsMotors 1115210 2125381 3130530 4110538 51.1--558 Station ImprovementsOptimal System % Improvement8.0%9.5%

22. Cost Analysis of Total System ImprovementCostOT Saved (After 2yrs) EOLT $ 12,000 Preventive Maintenance (4% output increase) $ 50,000 $ 144,000 Station 210 $ 1,500 Procedures $ 100 Station 90 $ 7,000Agreed to w/o Payback Total $ 70,600 $ 157,500 Estimated Cost Analysis Net Present Value

23. Conclusions All Deliverables were met Standardized Procedures Preventative Maintenance Set Production Guidelines Fix Problematic Stations End of Line Tester Efficiency Identify improved system configurations 9.5% improvement and met 2-year payback.

24. Acknowledgements Thank you: Mentor, Dr. Michael Kuhl Coordinator, Dr. Paul Stiebitz The entire Valeo Staff including Richard Guerin, Paul Vandeursen, James Ely.

25. Arena Model

26. Data Slides

27. PM Schedule

28. Industrial Standards Clean Room Certified Class 100,000 QS 9000 Quality standard TS 16949 Valeo Union Standard 423 minutes per shift Ergonomic Guidelines

29. Bill of Materials

30. Motor Count

31. Counter Data

32. Micro-Stops

33. Station 90 Time Study TypeTime Savings Body TurnTBC10.67 Reach Bin AC0.44 Reach Bin BC0.44 Body TurnTBC10.67 Reach Bin CC0.41 Reach Bin DC0.41 Body TurnTBC10.67 Reach Bin EC0.39 Reach Bin FC0.39 Seconds Saved4.4928s Avg. Process Time20.48s Percentage Savings21.94%

34. Regression

35. Process Time Bottleneck Ranks RankStationAvg Cycle Time 1EOL44.07 29036.93 316035.48 410022.18 5170A21.17 6140A20.85 7200B20.80 8110B20.50 9120B19.66 1021017.71 11140B17.20 1218016.85 1320516.69 14120A15.86 15150B15.07 1619015.01 17200A14.94 18110A14.88 19150A12.95 20170B11.65 21230B11.48 22230A10.78 231306.29

36. WBS