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Team Valeo

Team Valeo. Stefan Enjem – ISE Joe Van Hofwegen - ISE Young Lee - ISE Joe Pecht - ME Walter Freitag - ME Jason Zion - ME Luis Garcia - EE. Introduction. Product Goals Increase QPH 4 to 6% 2 year payback Safety and Quality. Production Line Layout. Continuous Counterclockwise Loop

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Team Valeo

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  1. Team Valeo Stefan Enjem – ISE Joe Van Hofwegen - ISE Young Lee - ISE Joe Pecht - ME Walter Freitag - ME Jason Zion - ME Luis Garcia - EE

  2. Introduction • Product • Goals • Increase QPH 4 to 6% • 2 year payback • Safety and Quality

  3. Production Line Layout • Continuous Counterclockwise Loop • Variable Staffing EOLT 90

  4. Areas of Improvement • Downtime • End of Line Tester • Leak and Snap Ring Test • Process Time • PCV Assembly Station • Procedures • Production Board • Preventive Maintenance • Work Flow • Pallet Flow Control and Failure Response • Alternative Configurations

  5. Downtime • Micro-stop - Downtime of less than 5 minutes # of Micro-stops/month

  6. Downtime: End of Line Tester • Purpose • Final Station before leaving clean room • Fully tests all motors • Problems • Downtime • Micro-stops • Causes • Existing Technology

  7. Downtime: End of Line Tester • Assembly Cell Design

  8. Downtime: End of Line Tester • Solution • Original system specs • Modifications required • Design • New connector

  9. Downtime: End of Line Tester • Finite Element Analysis • Benefits • Reduced downtime • Decreased operator interaction • Increased potential motor output by 7%

  10. Rubber Connectors Downtime: Leak and Snap Ring Test (210) • Leak Test • Problem • Solution • PM

  11. Downtime: Leak and Snap Ring Test (210) • Optical Test • Problem • False Failures / Glare • Solution • Mirror Assembly [Nerlite Doal-50-led] • Station Improvement Benefits • 1% increase in total motor output

  12. Process Improvement • Histogram shows major sources of backup

  13. Process Time: PCV Assembly (90) Before After • Problems: Process time, bin layout • Solution: Move part bins, Modify Program • Benefits: Reduction in assembly time (5 seconds), Ergonomically designed set up

  14. Procedures: Preventive Maintenance • Creation of a Preventive Maintenance Schedule • List of tasks to be completed on a weekly basis • Complete inspection of the line • Benefits • Increased reliability of stations • Reduction in catastrophic failures • Less disruption of production time • Similar PM programs show a 4% improvement

  15. Procedures: Visual Production Board • Performance Assessment • Communications Hub

  16. Work Flow Improvements • Pallet Flow Control • Inhibiting Release Logic • Failure Response Time • Minimizes blocking • Increases motor output EOLT 90

  17. Arena Simulation • Arena Model created to analyze system • Mimics the behavior of the real system • Interface for user created • Analyze potential system changes

  18. Arena Model: Background

  19. Arena Model: Set-up

  20. Arena Model

  21. Work Flow: Alternatives • Arena Model used to analyze system • Optimal configurations and results • Based on improvements made to the line: • Optimal Pallets is 47

  22. Cost Analysis of Total System • Estimated Cost Analysis • Net Present Value

  23. Conclusions • All Deliverables were met • Standardized Procedures • Preventative Maintenance • Set Production Guidelines • Fix Problematic Stations • End of Line Tester Efficiency • Identify improved system configurations • 9.5% improvement and met 2-year payback.

  24. Acknowledgements • Thank you: • Mentor, Dr. Michael Kuhl • Coordinator, Dr. Paul Stiebitz • The entire Valeo Staff including Richard Guerin, Paul Vandeursen, James Ely.

  25. Arena Model

  26. Data Slides

  27. PM Schedule

  28. Industrial Standards • Clean Room • Certified Class 100,000 • QS 9000 • Quality standard TS 16949 • Valeo Union Standard • 423 minutes per shift • Ergonomic Guidelines

  29. Bill of Materials

  30. Motor Count

  31. Counter Data

  32. Micro-Stops

  33. Station 90 Time Study

  34. Regression

  35. Process Time

  36. WBS

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