1. Phase I & II Short Form Presented to : Dr. John Sinn Prepared by: Team One – QS 327 Due: October 19, 2005

2. Team Members  Josh Bard  Curtis Bishop  Scott Chapman  Brad Cymbola  John Haver  Alice Kromer  Peter Maas

3. Phase I Summary  Startup Completion  Toolkit 19 Completion “Kaizen Documentation Foundations For Data Driven Process Variation, Waste Reduction, Lean Six Sigma”  Toolkit 20 Completion “Basic Economic Considerations, Cost Related Documentation For Kaizen, Lean Systems, Quality Relationships”  Toolkit 21 Completion “Ongoing Process Control Plan (OPCP), Standard Operating Procedures (SOP) For Lean: Infrastructure For Understanding Process”  Phase I Portfolio Completion

4. Phase II Summary  Toolkit 22 Completion "Synchronous Production: Enhanced Best Practices For Change, Lean, Variation Reduction“  Toolkit 23 Completion "Failure Mode And Effects Analysis (FMEA), Quality Function Deployment (QFD), Reliability For Robust Problem Solving"  Toolkit 24 Completion "Total Productive Maintenance, Safety And Ergonomics: Re- engineered Lean Environment"  Phase II Portfolio Completion

5. Course Objectives  Complete Toolkits 19-24, each containing 5 SDAs and 3 RCAs per toolkit. Continuously improving and adding value to each one based on the previous POAM Assessment.  Complete Phase I and II, incorporating most detailed and valued work throughout the course entirety, within the portfolio.

6. Project Focus  Process: Plastic Injection Molding  Product: Plastic Bumper Raw material stored in silo Raw material sent to drier units Raw material sent to press hoppers Raw material is run through press auger/barrel and injected into mold Part is ejected from press Part is trimmed Part goes to inspection Finished part goes to shipping

7. Tool #19 Content  ISO 9000 Streamlined: TS 16949 2002 basis for quality systems  Kaizen, six sigma, lean process for ISO, QS, documentation for quality  Traditional productivity tools, basic documentation for improvement  Using charts to solve problems, reduce variation, do six sigma  Quality characteristics, customers, and suppliers: Tying process improvement together  Characterstics, inspection, attribute, variable data, lean, six sigma  Data, documentation, evaluation

8. Tool #20 Content  Quality cost and waste: Kaizen, lean  Why are we in business—context for economic and cost considerations?  P and L, operating statement  Selected costs, Kaizen general cost analysis factors  Value analysis, value added, quality  Break even analysis  Capital investment analysis  Materials requirements planning, costs, work in process, line balancing

9. Tool #21 Content  Understanding process: Ongoing process control plan—OPCP  Standard operating procedures (SOP), Ongoing Process Control Plan (OPCP)  Team based problem solving, documentation, training functions, variation reduction for lean  8-D overviewed for solving problems  Role of the operator and others, ongoing improvement, broader issues  Traditional productivity tools, documentation for improvement, lean

10. Tool #22 Content  Context for synchronization, lean, best practices  Lean systems applied: kanban, takt, SMED  Total productive maintenance  Failsafing and Poka Yoke design: Enhanced problem solving tools  Best practices, bench marking, auditing  Applied technical research for synchronous, lean, kaizen  DOE Taguchi style research, PSDOE start point  Auditing our quality: Another evaluative tool

11. Tool #23 Content  Failure mode and effects analysis (FMEA)  The design process  Design, product and process FMEA  FMEA steps and procedures  Product liability, FMEA, reliability, finite element analysis (FEA)  General reliability issues, Kaizen and FMEA  Quality function deployment (QFD) for lean introduced

12. Tool #24 Content  Basic maintenance requirements and lean service relationships  Types of maintenance  Total productive maintenance, synchronous quality for lean  Safety, human factors, quality objectives  Safety and ergonomic management  Controlling physical conditions for ergonomic enhancement

13. Phase Compilations  Each toolkit is built on the team member’s individual contribution to the tables assigned. The project focus is applied to the concepts behind these specific tables. Each member then compiles their assigned table(s) showing everyone’s individual work and FACRs. The final compilation is then completed by the team leader.  The Phase I Portfolio is a compilation of the work completed through toolkits #19-21. The Phase II Portfolio is a compilation including Phase I content and toolkits #22-24. Both reflect the best and most thorough submitted toolkits throughout the course.