Enhancing Resource Availability in the Wire Harnessing ... · High performance assembly jig •...
Transcript of Enhancing Resource Availability in the Wire Harnessing ... · High performance assembly jig •...
Enhancing Resource Availability
in the Wire Harnessing
Department for FORCE America
KaytLynn Riel
Milwaukee School of Engineering
August 29th, 2018
Agenda
Background
Problem
Data Collection
Improvement Alternatives
Recommendation
Company Background
FORCE America was Founded1953
Electrical Division In-House1992
Project Background
Production Schedule
Job Packets
Tooling
Problem Statement
Scheduling
with PriorityResource Sharing
Scope
Develop Baseline Metric
Examine Tooling
Capacity
Understand Production
Scheduling Factors
In S
co
pe
Ou
t o
f S
co
pe
Product Design
Examine Wire
Storage Area
Product Quality
Data Collection and Analysis
Resource Availability Study
MPX Model
Production Scheduler Interview
Data Collection and Analysis Continued
Resource Availability Study
1.83 Shares per Shift
Record Time Waiting
or Sharing Tools
183.4 Harnesses in
Lost Production a Year
Project Objective
1.83
0.50Shares per Shift
Shares per Shift to
Information Collection:
9 Product and Tool Families
37% Wire Harness Demand
MPX Model
Key
App Applicator
HT Hand Tool
Data Collection and Analysis Continued
Scheduling with Tooling
Environment MachineMan
Software
Excel
AX
Hard to Tell Who has What Tool
Walking Required for Equipment Retrieval
Slow Production PaceProduction Lead for Wire
Harnessing
Production Scheduler for Wire Harnessing
Process Time Accuracy
Tooling at Stations are not Used 100% of the Time
Hand Tools
Required Tooling Visibility
Harness Number
Business Add-On
Job Packet
Floor Scrap
Manufacturing Floor
Schedule Similar Products at the Same Time
Change Schedule Multiple Times a Day
Assemblers in Wire Harnessing
Applicators
Job Packet
Production Scheduler Interview
Data Collection and Analysis Continued
Improvement Alternatives
Schedule Generator with Tooling
Real-Time Production Schedule
Digital Note Sheets
Digital Work Instructions
Improvement Alternatives Continued
Item Value
Initial Cost $ 4,880
Annual Benefit $ 8,452
Interest Rate 9%
Payback Period 7.43 Months
Features
Identify Tooling Required
Auto-Organize Tooling Based on
Priority
Benefits
Reduce UnnecessarySetup Time
Reduce Sharing to 0.5 Shares
per Shift
Costs
Program Development
Training
Schedule Generator
with Tooling
Improvement Alternatives Continued
Features
Auto-Update Production
Schedule on Floor
Identify Available Tooling for Production
Benefits
Reduce UnnecessarySetup Time
Reduce Sharing to 1.0 Shares
per Shift
Costs
Program Development
Barcode Scanner
Item Value
Initial Cost $ 1,760
Annual Benefit $ 9,990
Interest Rate 9%
Payback Period 2.23 Months
Real-Time
Production Schedule
Improvement Alternatives Continued
Features
Electronic Data Record
Improve Data Access for Employees
Reduce Paperwork Scanning
Costs
Program Development
Computer Components for
Each Cell
Item Value
Initial Cost $ 9,049
Annual Benefit $ 650
Interest Rate 9%
Net Present Value $ (1,831)
Digital Note Sheet
Benefits
Improvement Alternatives Continued
Digital Work
Instructions
Features
Interactive Work Instructions
Improve Data Access for Employees
Benefits
Reduce Paperwork Scanning
Reduce Unplanned Labor Cost
Costs
Program Development
Computer Components for
Each Cell
Item Value
Initial Cost $ 25,953
Annual Benefit $ 10,450
Interest Rate 9%
Payback Period 35.23 Months
Recommendation
Schedule Generator
with Tooling
Recommendation Development
Enter Production Information
See Results with
Conflicts
See Results in Gantt Chart
Thank You!
PRESENTED BY
VSA Partners
CONFIDENTIAL
StratasysThe Power of Additive. Applied.
Factory Floor Solutions
July 2018
The Power of Additive. Applied.
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Common applications
• Assembly fixtures
• Check gauges
• Surrogate parts
• Protective covers
• Tool organizers
• Part cradles
• Forming tools
• Drill jigs
• Badge alignment fixtures
• End of arm tooling
• Ergonomic handles
• Replacement parts
• CMM fixtures
Additive Manufacturing on the Factory Floor
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Additive Manufacturing on the Factory Floor
LEAN Manufacturing
• Eliminating Waste
• Continuous Improvement
• 5S
Ergonomic Design
• Productivity
• Safety
Total Productive Maintenance
• Uptime
• Cost savings
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• Eliminating waste
Additive is FLEXIBLE. It is applied throughout the value stream to speed production, improve quality and minimize downtime
• Continuous improvement
Additive is FAST. It improves flow through the factory by allowing quick iterations of your solutions
• Organizing workspaces
Additive is FIVE S. It allows for infinitely customizable workspaces insuring the right parts and tools are quickly and safely accessible
LEAN Manufacturing
ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
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ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
LEAN Manufacturing
High performance assembly jig
• Used to install rubber door seal onto frame
• ULTEM 9085 and Nylon 12 with integrated
components produced a tool that was over
100 pounds lighter than predecessor
• Allowed for a 4 second per cycle decrease,
with over 250,000 cycles per year
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ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
LEAN Manufacturing
Rubber tube clamp for nitroglycerin
• Old ball valve design was easily
contaminated and needed to be replaced
frequently
• After two iterations, the tool works great
• Only Stratasys Nylon12 CF had the
strength required to print this clamp
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ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
LEAN Manufacturing
Inspection tool for auto air conditioner
• Fixture to validate production part in
South Korea
• Printed in ASA, combining strength,
aesthetics and durability for the
application
• Tool needed to be designed, printed and
shipped within one week, vs 4-5 weeks
for CNC
• Lighter and $1000+ less expensive than
CNC machined fixture
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ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
LEAN Manufacturing
Angled splitter bung machining fixture
• Fixture allows for small holes to be
clocked in various positions
• Relatively high volume engine part
needed repeatable and reliable process
• Simple additive fix to complex machining
problem
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ADDITIVE MANUFACTURING and STRATASYS EXPERTISE can meet the LEAN demands of today’s factories.
LEAN Manufacturing
5S shadow board
• Machine specific tools readily available
• Small improvements can provide big
savings
• Flexibility to change for new parts or
operations
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Ergonomic Design
Workplace injuries cost US manufactures over $62B annually.
Overexertion is the number one cause of injuries accounting
for over 25% of this cost - 2016 Liberty Mutual Workplace Safety Index
• Engineered materials
Additive can replace metals in many applications, reducing weight and improving quality and safety
• Design for additive
DFAM allows for designs with strength just where it is needed
• Human factors
Tooling can be custom fit to operators of different sizes, abilities and hand dominance
With the design freedom of Additive Manufacturing and Stratasys materials, tooling can be LIGHTER WEIGHT and ERGONOMICALLY DESIGNED resulting in improved processes and fewer injuries
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With the design freedom of Additive Manufacturing and Stratasys materials, tooling can be LIGHTER WEIGHT and ERGONOMICALLY DESIGNED resulting in improved processes and fewer injuries
Ergonomic Design
Torque verification and connector
adapters
• Existing process was causing injuries
and affecting worker morale
• Connector adapter took 3 hours to create
from initial measurement to
implementation
• Torque verification puck improved
throughput and operator satisfaction
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With the design freedom of Additive Manufacturing and Stratasys materials, tooling can be LIGHTER WEIGHT and ERGONOMICALLY DESIGNED resulting in improved processes and fewer injuries
Ergonomic Design
Rocker lever spring compressor
• Pneumatic compressor tool with printed
handle, guard and structure
• Previous operation required two
operators
• Printed tool reduces safety risk and
improves quality
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With the design freedom of Additive Manufacturing and Stratasys materials, tooling can be LIGHTER WEIGHT and ERGONOMICALLY DESIGNED resulting in improved processes and fewer injuries
Ergonomic Design
Conductive pick handle
• Existing tool was difficult to use
• Assemblers modified tool with
Moxi tape
• New 3D printed tool designed
to fit hand
• 100s printed to meet assembler
demand
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Total Productive Maintenance
• Virtual inventory
• Reduced number of vendors
• Shorter lead times
• No minimum order quantities
• Just-in-Time, not Just-in-Case
Additive manufacturing can provide direct replacement parts and process improvements for the most demanding industrial applications
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Additive manufacturing can provide direct replacement parts and process improvements for the most demanding industrial applications
Total Productive Maintenance
Wrapping machine replacement part
• Mis-fed would cause downstream damage on
machine
• Replacement metal part had long lead time
• Printed part is 83% less expensive and takes 49
minutes to print
• Part was designed as a mechanical fuse to
prevent downstream damage
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Additive manufacturing can provide direct replacement parts and process improvements for the most demanding industrial applications
Total Productive Maintenance
Hydroforming tool
• Emergency landing caused damage to a single
stringer in the nose which had impacted the table
• Rather than ordering from an OEM or
remanufacturing the part, they designed a set of
doublers as structural reinforcement
• Forming tools were printed overnight in PC
• Parts were formed that same week via
hydroforming
• Aircraft was back in service within 1 week
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Dimensionally correct parts the first time, every time.
• Print confidence means greater machine uptime
• Easy to use requiring less engineering and operator labor
• Production grade system for years of reliable service
Over 30 years of expertise.
• Application knowledge
• Design for additive
• Software that secures design intent
More materials. Better solutions.
• Leader in additive formulations
• ABS, ASA, PC, Nylon12CF, Ultem,…
Why STRATASYS?
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Identify pain points / Opportunities
• Visual factory boards
• Kaizen events
• Daily stand-up meeting
• Factory walkthroughs
Engage / educate
• Local manufacturing engineers / tooling designers
• Stratasys AEs
Implement
• Plan Do Check Act
• Document benefits and scale
Implementing Additive on the Factory Floor
Wayne BensonDirector, Factory Floor [email protected]