1. Subsystems Design Review Nathan Arrowsmith, Samantha Reinhart, Rachel Short, Yelena Tuzikova

2. Concept Selection - Revisited Arrange by Part Family with Flow Racks Arrange by Kits Arrange by Part Number with Bins Arrange by Assembly Sequence with Bins Arrange by Machine Arrange by kits in U-shaped cell Underlying Principles - Replenishment and retrieval is compartmentalized - Parts can still largely be placed near POU/corresponding machines -Minimal inventory in cells -Inventory accuracy -Locating parts is as easy as counting -Easy for new employees and water spider -Minimize motion waste in cell/bins easily accessible -Improved cycle time of assembly -Ergonomic -Minimize motion within the cell -Easy replenishment -Visual management -Minimal inventory in cells -Inventory accuracy Cons- Mixed use parts can end up far from POU -Kits need set-up - Parts are rarely at POU -Movement waste -Need parts in multiple assemblies -Extra tabletop storage needed to be ergonomic -Kits need set-up Constraints-Flow racks require structural changes that might reduce space inside cell -No central storage -Employee approval -Inadequate space at assembly location -Not enough space around machine to store all components -Would need to rearrange / re-layout cell -No central storage

3. Cell Overhead Two Aisles Left: Aisle 1 Main assembly POU Storage Right: Aisle 2 Repack Kitting Overflow Storage

4. Aisle 1 Left Right

5. Aisle 2 Left Right

6. Underutilized Space in 922A Aisle 2 has the most under-used space. Note: Most of the space in red is dedicated to repack. Repack materials arrive so inter- mittently that we assumed that this was flex space until Jen clarified its use.

7. Material Presentation Rules Visual: 1.Fabricated and Purchased items will be kept in yellow bins with yellow or white labels. 2.VMI items in another color bin (purple?) 3.Electronics stored in black bins 4.Purple card placed inside bin when the kanban card is removed and the part is on the ordered item list 5.Shared part storage must be labeled with name of primary/owner cell 6.Bin locations must be labeled as well as the bins Storage: 1.Store one days worth of corrugated and VMI inside the cell 2.Dedicated storage for overstock including one big bin for fabricated overstock parts 3.Flexible location for infrequently used parts 4.General rules for highest usage parts

8. Part Storage Rule Ideas Only Kanban items are included so far - working on obtaining order quantity information These parts require a total volume of ~21 cubic feet 1.Categorize items by unit volume x (2 Kanbans - 1 unit) into S, M, L, and XL amount of bin storage needed 2.Dial and rod parts will have non-bin storage, not based on volume CategoryStorage Volume (in^3) Count S<0.523 M<1044 L<10048 XL>10028 DialN/A30 RodN/A17

9. Test Plans and Metrics to Verify Design Test Plans Kitting components for a day’s worth of work ❖ Operator kits own parts from a ‘central location,’ only takes what needs for ‘x’ number of jobs that day. Assembles in cell. ❖ Persons needed: Jen, Team Arrange parts by machine Arrange parts by assembly sequence ❖ Search for VMI parts in current state, and then after our rules are implemented ❖ Given an assembly BOM; how long to find parts? ❖ What Kanban cards have been turned in? How many steps do they take? ❖ How close is this parts Kanban size to the actual given number of parts on hand? ❖ Persons needed: Jen and/or Kurt, Team Alternative Cell layouts ❖ Single aisle “U-shape” ❖ “U-shape” cell with flow rack at front Metrics Measured ❖ Time spent looking for parts ❖ How many times a day is a part needed that they don’t have a Kanban card for ❖ Inventory Accuracy (may be difficult to measure- how closely does reality match system?) ❖ Distance travelled: Spaghetti diagrams

10. Project Plan