2. 1 BOWLING GREEN STATE UNIVERSITY College of Technology TECH 626 (Spring 2001)

3. 2 TECH-626 TEAM PROJECT Phase-2 (final) Presentation LEC Rotational Molding Machine Quality & Reliability Assessment

4. 3 TEAM MEMBERS TEAM MEMBERS Steve Gormley Diane Patino Chandana Hewavitharanage Chandana HewavitharanageINSTRUCTORDr.J.W.Sinn (Professor-College of Technology, BGSU)

5. 4 THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS The Rotational Machine Operation Area (pic 01)

6. 5 The Rotational Molding Machine (pic 02) THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont. THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont.

7. 6 The Rotational Molding Machine – cont. (pic 03) THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont.

8. 7 The Rotational Molding Machine - cont. (pic 04) THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont.

9. 8 The Rotational Molding Machine – cont. (pic 05) The Rotational Molding Machine – cont. (pic 05) THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont. THE ROTATIONAL MOLDING SECTION’S CURRENT OPERATIONS - cont.

10. 9 Molded LEC Body Molded Body

11. 10 PRODUCT DESCRIPTION The Acme Lifeline Emergency Cart (LEC) is a fully functional crash cart designed from the ground up to meet the critical demands of a hospital “code.” A “code” is among the most critical of all hospital emergencies. Efficient code response saves time and lives, and that is where a LEC unit comes into play.

12. 11 LEC’s FEATURES Quick, safe transport of vital supplies to the code sites. Quick, safe transport of vital supplies to the code sites. Simultaneous access by multiple code team members. Simultaneous access by multiple code team members. Self-contained vehicle, perfect for medical / surgical floors where vital equipment may not be readily available. Self-contained vehicle, perfect for medical / surgical floors where vital equipment may not be readily available. Clear, logical organization and identification for all types of supplies. Clear, logical organization and identification for all types of supplies. Convenience features include integrated backboard, gel bin and I. V. bins. Convenience features include integrated backboard, gel bin and I. V. bins. Advanced design polymer materials are rugged, durable, yet lightweight, rustproof and easy to clean. Advanced design polymer materials are rugged, durable, yet lightweight, rustproof and easy to clean. Fully enclosed unit with visible security checks. Fully enclosed unit with visible security checks.

13. 12 PROBLEM STATEMENT assembly Acme’s Lifeline Emergency Cart (LEC) assembly line resembles a traditional batch and queue operation. Due to competition and rising production costs, Acme is forced to implement new systems and approaches to increase productivity and quality at lower cost. Team has selected Rotational Molding Machine operations, a critical area of current operations, and will present a proposal to improve quality and productivity.

14. 13 OBJECTIVES Improve Safety and Ergonomics Improve Safety and Ergonomics - Improve GSIC score by 90% - Improve GSIC score by 90% - Improve 5S Score by 425% to achieve 85% - Improve 5S Score by 425% to achieve 85% Improve Quality Improve Quality - Reduce scrap by 85% - Reduce scrap by 85% - Determine Process Capability - Determine Process Capability - Redesign Product according to Process - Redesign Product according to Process Capability where needed Capability where needed - Improve Process Capability where needed - Improve Process Capability where needed (warp & shrink?) (warp & shrink?) - Achieve and maintain a minimum of 1.33 CPK of - Achieve and maintain a minimum of 1.33 CPK of all Critical to Quality Parameters all Critical to Quality Parameters

15. 14 OBJECTIVES – cont. Reduce Costs with new techniques -Reduce scrap by 85% Acquire proper tooling Develop Preventive Maintenance System

16. 15 MAJOR STEPS 1. Thorough data collection and analysis of Acme’s LEC Roto-Molding Machine of Acme’s LEC Roto-Molding Machine Station. Station. 2. Propose preliminary quality 2. Propose preliminary quality improvements improvements 3. Calculate Return on Investment 3. Calculate Return on Investment 4. Decide on proposed improvements 4. Decide on proposed improvements 5. Develop training curriculum 5. Develop training curriculum cont. cont.

17. 16 MAJOR STEPS (cont.) 6. Detail Improvements 7. Implement 7. Implement 8. Feedback Analysis 8. Feedback Analysis 9. Sustain 9. Sustain

18. 17 GENERAL INDICATORS/ CHARACTERISTICS GENERAL INDICATORS/ CHARACTERISTICS Safety and Ergonomics: Worker fatigue Worker fatigue Heavy tooling Heavy tooling Location of materials Location of materials Movements Movements Worker morale and Worker morale and overall safety through 5 “S” overall safety through 5 “S”

19. 18 GENERAL INDICATORS/ CHARACTERISTICS - cont. Quality: Better finishing look Better finishing look Wastage of materials Wastage of materials Handling of products Handling of products Workers knowledge in quality functions Workers knowledge in quality functions Worker morale in quality improvements Worker morale in quality improvements Quality standards Quality standards

20. 19 GENERAL INDICATORS/ CHARACTERISTICS cont. GENERAL INDICATORS/ CHARACTERISTICS cont. Reduce Costs : Recognizing non-value added processes and eliminating them accordingly Recognizing non-value added processes and eliminating them accordingly Reduction of materials wastages through proper handling and methods Reduction of materials wastages through proper handling and methods Better productivity levels to reduce unnecessary time through SOPs Better productivity levels to reduce unnecessary time through SOPs (Quality Management) (Quality Management) Reduce defect rates through proper quality standards ( Quality Management) Reduce defect rates through proper quality standards ( Quality Management)

21. 20 GENERAL INDICATORS/ CHARACTERISTICS – contd. GENERAL INDICATORS/ CHARACTERISTICS – contd. Decrease Cycle Time: Wasted movements Wasted movements Poorly located tooling Poorly located tooling Unorganized work station Unorganized work station

22. 21 GENERAL INDICATORS/ CHARACTERISTICS – contd. Develop Preventive Maintenance: Excessive training Develop Preventive Maintenance: * Excessive training * Introduction of better PM * Introduction of better PM methods methods * Introduction of Preventive * Introduction of Preventive Maintenance Management Maintenance Management Systems Systems

23. 22 STATISTICAL ANALYSIS

24. 23 STATISTICAL ANALYSIS CONTD.

25. 24 STATISTICAL ANALYSIS CONTD.

26. 25 STATISTICAL ANALYSIS CONTD.

27. 26 STATISTICAL ANALYSIS CONTD.

28. 27 APPLICATION FORMS APPLICATION FORMS 1. RCA: OPAQAFL/ IRAA / TAA/ TPMA/ TPMAF/ OBACDS 2. SDA 2. SDA : MMA/ GSIC /GWSC /PC /CA/FMEA/ 5S Program/ Cause and Effect Diagram / CI/ ITC/ CA/VSRC/CTTIC/VSRC 3. RCA: TPMA/TPMAF/OBACDS

29. 28 TEAM EVALUATION Quality of the weekly postings has been improved. Quality of the weekly postings has been improved. On-line meetings took more organized On-line meetings took more organized approach with the beginning of approach with the beginning of phase 2. phase 2. Timeliness was not improved due to various reasons. Timeliness was not improved due to various reasons. Good team approach and team work. Good team approach and team work.

30. 29 TEAM’S CURRENT GOALS Apply the suggested and developed ideas with appropriate techniques to the Current Operations in the manufacturing process. Apply the suggested and developed ideas with appropriate techniques to the Current Operations in the manufacturing process. To complete the phase 2 as best as possible. To complete the phase 2 as best as possible. Once Completed, Publish the Project in a Recognized Academic or Professional Journal. Once Completed, Publish the Project in a Recognized Academic or Professional Journal. ( in this regard already arranged the necessary steps) ( in this regard already arranged the necessary steps) To Obtain a “ A” Grade for the TECH 626. To Obtain a “ A” Grade for the TECH 626.

31. 30 The End

32. 31 We, 2001 (spring) TECH 626 team, take this opportunity to thank Dr. J.W. Sinn for his guidance, encouragement, numerous helps, and flexibility we have been receiving since the beginning of this course.

33. 32 Thank You Please see the attached phase 2 file (final draft) for more details. (final draft) for more details.