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Terumo Cardiovascular Systems: Oxygenator Production Improvement

Terumo Cardiovascular Systems: Oxygenator Production Improvement. University of Delaware’s Senior Design Team: Tom Craig Mike Giuliano Ronit Lilu Chase Ross Kate Staley. Description of Project. Project Goals:

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Terumo Cardiovascular Systems: Oxygenator Production Improvement

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  1. Terumo Cardiovascular Systems:Oxygenator Production Improvement University of Delaware’s Senior Design Team: Tom Craig Mike Giuliano RonitLilu Chase Ross Kate Staley

  2. Description of Project • Project Goals: • Improve the efficiency of Reservoir Assembly production line via reduction in downtime, change over time, and cycle time. • Employ lean manufacturing techniques from the ground up such as participation in a Kaizen event

  3. Assembly Line Reservoir Inspection Lid Assembly VR Station CR Station Leak Tester VR CR Lid Final Assembly Lid Line Jig

  4. Current Floor Layout vs. Future Floor Layout Reservoir Assembly Table CR VR Lid Line Assembly Table Product Flow

  5. Lean Manufacturing Techniques • The Kaizen event: • Attended a meeting with representation from operators, manufacturing, production supervisors, engineering, and plant leadership to discuss improvements • Time study • Spaghetti diagrams • Value Stream Mapping (VSM) • Value Added, Non-Value Added Time

  6. Customers & Wants • Customers: Terumo Management, Terumo’s Floor Staff, Surgeons, Hospitals, Patients

  7. Metrics and Target Values

  8. Current Floor Layout vs. Future Floor Layout Product Flow Reservoir Assembly Table 1 Pass of 3 Steps 6 Passes of 3 Steps Each CR VR Lid Line Assembly Table • VR walking distance/day ≈ 6.6 miles • CR walking distance/day ≈ 1.5 miles • VR walking distance/day ≈ .5 miles • CR walking distance/day ≈ 0.3 miles

  9. VR: Current State vs. Future Current State Future State Time Saved: mostly due to table redesign and offline production Walking Time - 6.3 seconds

  10. VR Concepts • Rotate lid assembly table and align it with Chemical Table • Redesign Chemical Table and “L” it with the assembly line • Design and manufacture additional jig • Take wings off jigs on table • Sensors on bins to force order

  11. CR: Current State vs. Future State Current State Future State Time Saved: 9.9 seconds reduced time through elimination of walking (moving caps) and addition of the chemical sensor. Note: Increased VA time due to addition of inspection tasks

  12. CR Concepts • Move caps down to reservoir inspection • Time sensor for chemical dipping • Move CR cart closer to operator • Increase inspection duties

  13. Reservoir Inspection: Current State vs. Future State Current State Future State Reduction in Inspection Duties Line Balancing: Additional responsibilities (placement of 6 more caps)

  14. Proposed Floor Layout Table at CR Station Table at VR Station

  15. Final VR Table Tricots Drainage cages Fume hood Small tubes Large tubes Jig Position forcing tray

  16. Preparation before Implementing • Risk Analysis • Met with a team of Terumo associates including engineering, upper management, quality manager, and manufacturing associates to assess risk via a Terumo Risk Analysis template. • Given GREENlight to go ahead • Update Standard Operating Procedures • Drafted changes to the SOP via text and pictures which was then reviewed and approved by Terumo

  17. Implementation/Testing • Off-line implementation • Operator at Terumo tested the new set-up of VR table on manufacturing floor to make sure everything easy to reach and functions well.

  18. Implementation/Testing • Parts were loaded into bins to test how much they hold. • Improvements: • Tricot and drainage cage bin sizes increased to increase capacity • Positioning adjustments made

  19. Performance Metrics

  20. Path Forward • Terumo will manufacture the new bins for the increased capacity and new arrangement. • Design can then be implemented on the line. • Additional time studies and spaghetti diagrams are recommended once implemented on the line. • Sensors will be implemented at a later date by Terumo.

  21. Project Cost Note: Terumo will use their own Machine Shop to manufacture the jig and VR Chemical Hood. Team will use UD Machine Shop to manufacture bins.

  22. Revenue Analysis • 15 additional units/hour • 30,960 additional units/year • $12,384,000 additional revenue/year • $1,145,520 additional material cost/year • $11,238,480 net gain/year

  23. Project Summary • Lean manufacturing techniques such as VSM used to increase efficiency of manufacturing process • Improved ergonomics for operators • Maximized space used • Decreased cycle time • $11.2 million net gain/year

  24. Questions?

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