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The Angel & The Dinosaur. Origami Production Project. Objectives of Project. Simulate a production activity (in Etcheverry 4193) Learn a little bit about many relevant IEOR concepts covered in later courses Gain experience in teamwork and report writing Have fun competing with your peers
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The Angel & The Dinosaur Origami Production Project
Objectives of Project Simulate a production activity (in Etcheverry 4193) Learn a little bit about many relevant IEOR concepts covered in later courses Gain experience in teamwork and report writing Have fun competing with your peers Do something useful
Use of Product • The product will be given to children in hospitals. • Teams are asked to write personal notes of encouragement on the bottoms of the origami objects.
(In-class) Competition Dates Friday, December 9 GSI office hour: Tuesday (Dec 6) from 12:00-1:00 at 1171 Etcheverry (DECF computer lab)
Real-World Parallels Everything you do in this project is either the same as, or closely parallels, things you would do in a real manufacturing project. The principal difference is the scale of the project – not the content.
How to make the objects Go to the web sites http://dev.origami.com/images_pdf/angel_fehl.pdf http://dev.origami.com/images_pdf/ptrex.pdf Read the instructions – also see handout.
Project Description Teams of four or five will have 5+5 minutes to produce angel & dinosaur origami models from square sheets of paper. Team assignments have already been made.
Project Rules Teams can “buy” provided paper in four ways - Bulk pack (10 sheets) uncut (8 ½ x 11) $4 /sheet $40 /pack Pair uncut (8 ½ x 11)$6 /sheet $12 /pair Bulk pack (10 sheets) precut (square)$7 /sheet $70 /pack Pair precut (square)$9 /sheet $18 /pair Note that you can only make objects from 8 ½ x 8 ½ size paper. Nothing smaller will be accepted
Wage Charges Wages will be charged per person per 5 minute period Quality standard setting time: for the first 5 minutes - $4/person/5 minutes Regular time: for the next 5 minutes - $4 /person /5 minutes Overtime: for the next 5 minutes - $8 /person /5 minutes
Quality Standard Setting Time Each team will have 5 minutes before the main production time to make 3 PERFECT dinosaurs and 1 PERFECT angel Penalty All 4 perfect: no penalty 3 perfect: $15 penalty 2 perfect: $30 penalty 1 perfect: $45 penalty 0 perfect: $60 penalty Objects made in this period is NOT for sale. In other words, they will not be counted in the total count
Disposal Fees Teams having extra strips from trimming their own paper must pay disposal fees. The first 20 strips will not be charged for. Waste management will then charge $1/strip after 20. The fee will be calculated by using the total number of 8 ½ x 11 sheets bought, so even uncut 8 ½ x 11 sheets will be subjected to the fee.
Poor Quality Disposal Fee A $1/unit charge will also be applied to all models not bought because of unacceptable quality. Your paper supplier will not accept returns. Once you buy the paper, it’s yours.
Selling Prices Selling price is $20/unit for each dinosaur, and $40/unit for each angel. The selling price is reduced by $5 for each defect down to half price for both the dinosaur and the angel – and then to zero. Assume you can sell everything of acceptable quality you can make.
Production Considerations Production: Paper may be stacked for cutting; however, great care must be taken to get a square cut. Uneven cuts result in defects. Teams choose their own production method. Some methods are more productive than others; it pays off to spend the time to find a good one. In addition, not all team members must work for the entire 15 minutes.
More Production Considerations Teams must produce a high quality product by making sharp, even folds. Any angel or dinosaur of unacceptable quality will not be bought. Teams need not follow the origami instructions exactly, but their product should be just as good as ones made by following the instructions (design for manufacturability).
Quality Warning!!!!! • Past experience indicates that the biggest difficulty teams have is making a high quality product!
Typical Quality Problems Poor folds Lack of symmetry Extra bends in paper Failure to follow folding instructions
Quality Control • Each team will have a Quality Control Inspector (QCI).
The QCI will compare each origami object with a gage-standard object, and write the number of defects on the object; sign a quality statement certifying each object was compared to the standard and all defects were noted; be assisted by the production team in sorting the objects by defect count (0,1,2,(3,4), scrap);
The QCI and the production team will have 5 minutes after final assembly to inspect and sort finished goods – any remaining objects count as scrap; may participate in fabrication or inspection during fabrication; time is charged at the same rate as the fabricators. “free”
Customer Quality Audit • The instructors will perform a customer quality audit at the end of the 10-minute QC and sort period. • Any finished goods with more defects than recorded by the QCI will be subject to a $10/piece non-conformance quality penalty.
Production Hints Hints: Adequate time will be given to plan for the project. Start early by practising making the models. Once the learning curve is negligible, think about the most efficient way to set up your production method. Next, look at your costs, and think of ways to modify your assembly after certain points in production.
Product Mix Decision An angel sells for more than a dinosaur, but its unit production time is slightly greater than that of a dinosaur and it is hard to make an angel with no defects. Thus, your company has a product mix decision: to decide on the number of each type of unit to produce.
Raw Material Purchase Decisions Buying uncut paper is cheaper. However, once waste management starts charging you for disposal of the strips, you may want to consider buying the paper precut.
Buying in Bulk, Disposal Charges Similarly, buying paper in bulk is cheaper than buying it in pairs. However, since paper unused at the end of production has no rate of return and is subject to disposal fees, teams may want to buy it in pairs towards the end of the time limit.
Overtime Wages Since wages increase up to double in overtime, teams should look at their revenues and costs carefully at this stage, since profits will decline sharply and could even turn to losses.
Wage Charges Wages are charged on a 5 minute basis. A team member who stops working after 8 minutes will still be charged for 10 minutes.
Winning is Sweet • The team making the most profit per team member wins the competition, and receives a special certificate.
Grading 25% is based on profit per team member 65% is based on the written project 10% is based upon professionalism—individual and team grades may be impacted by professionalism transgressions
Origami Day: Big Picture Paper is provided (teams may bring own scissors instead of renting them. Rulers may be used for any purpose). We take time in class to get set up. We have the quality standard setting period. We set up for the regular time period. We have the regular time production period. We set up for overtime. We have the overtime period.
Origami Day: Big Picture QC and sort period for 5 minutes. Buyers decide which products to buy, based on quality, and make purchases. We complete team accounting forms. Team productivity data is displayed on board or electronically. A most profitable team is determined.
Report Organization cover page with title, date, names of authors, and pledge signed by all authors - reports without signatures will not be graded executive summary: a brief synopsis of report contents (no more than half a page) table of contents explanation of the activity how your team analyzed the problem and prepared for the competition
Report Organization What you learned from this project? How can you do better next time? your evaluation of the competition; its plusses and minuses
Concepts to Explain w. Project Bill of materials Process flows Layout Line balancing and assembly methods Work Design Total Quality Management & Quality Control Jigs, fixtures, special tools Design for manufacturability
Concepts to Explain w. Project Product rework Product mix Learning/startup effect Regular time versus overtime production Inventory: raw material, in-process, finished goods Cost accounting Job enrichment Dealing with suppliers, and dealing with customers Reverse engineering
Report Due Date Friday, November 11, 4 PM. Leave the report (the exam) in my mailbox. Late reports receive a grade of zero.
Summary We emphasize • Quality • Competition • Report Writing • Productivity • Teamwork • Professionalism
A Last Word • We are not trying to make you Origami experts. • We are trying to introduce you, in an interesting way, to concepts you will learn more about in follow-on courses.
