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

1. BOWLING GREEN STATE UNIVERSITYCollege of TechnologyTECH 626(Spring 2001)

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

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

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

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

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

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

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

9. Molded LEC Body Molded Body

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.

11. LEC’s FEATURES • Quick, safe transport of vital supplies to the code sites. • Simultaneous access by multiple code team members. • 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. • 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. • Fully enclosed unit with visible security checks.

12. PROBLEM STATEMENT • 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 Machineoperations, a critical area of current operations, and will present a proposal to improve quality and productivity.

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

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

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

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

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

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

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

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

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

22. STATISTICAL ANALYSIS

23. STATISTICAL ANALYSIS CONTD.

24. STATISTICAL ANALYSIS CONTD.

25. STATISTICAL ANALYSIS CONTD.

26. STATISTICAL ANALYSIS CONTD.

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

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

29. TEAM’S CURRENT GOALS • 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. • Once Completed, Publish the Project in a Recognized Academic or Professional Journal. ( in this regard already arranged the necessary steps) • To Obtain a “ A” Grade for the TECH 626.

30. The End

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

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