Planning & Execution
Current revisions of working documents can be found in the Project Management directory.
|Alex Offredi||ME, Controls and Automation Engineer|
|Ericka Larssen||ISE, Project Manager|
|Mischa Dombovy-Johnson||ME, Design Engineer|
|Keshav Francis||ME, Lead Engineer|
|Daniel Consolazio||ME, Assembly Engineer|
Project Plans, Agenda, and Risk Management
Problem TrackingLive Problem Tracking
Customer Interaction and Meeting Notes
Customer Interview QuestionsQuestions asked during the MSD team's various interviews with the customer:
- AAT Phone Interview Final Questions [8/28/14]
1. How many operators are currently involved in the oil and bag process on a daily basis?
2. What is the average length of a shift for an operator?
3. What is the diversity in age/length of employment at AAT for the current operators? (Old vs. New)
4. What sort of training are new employees required to do?
5. Do the employees receive any ergonomic/safety training?
6. What are the average heights and statures of the current operators? (Can Include Hand size)
7. What kind of PPE is available for the operators to wear? Is PPE required for the process? If not required do operators wear PPE by choice?
8. Are there any operators that we can contact to learn more about their personal experiences?
9. What is the environment around the oil and bag process? Is it conducted in an appropriate workstation?
10. How often does the system run per day? Cycles and hours.
11. Could you explain the entire process step by step, including prepared for operation and clean up?
12. Are the nozzles placed in a fixture for the process? If so, how are they constrained?
13. What are the different components of the system? Their materials?
14. Are the individual components replaced? If so, how often?
15. Are there currently any concerns about the current oil containment system in place?
16. At which stages(s) throughout the process are the operators most at risk to come into contact with the oil?
17. What are your main concerns for the oil and bag process? Any personal experience?
30 Min Conference Call with Jim Kalinksi, Carl Waterman, and Chris (Operator) [8/28/14]
- Point of Contact: Jim Kalinski, Cell: 315-573-0034 E-Mail: email@example.com
- New employees start at Oil and Bag Process
- Receive machine operation training
- Provided with safety glasses and gloves
- Open toed shoes are prohibited
- Constant bending and reaching down has resulted in back injuries
- Ergonomic and safety issues for operators are biggest concern
- Every nozzle must go through the oil and bag process
- The workstation is currently non-adjustable
- Machine is old (about 20 years) and has no prints
- Nozzles are made from high grade steel
- Confirmed that same system is still in use
- CFM Nozzle Information
- One common point in every flange
- Several styles of CFM nozzle
- One coupler for all styles of CFM nozzle
- 140 CFM parts go through process per day
- Process occurs during 2nd shift
- Entire process takes about 1 minute
- Process runs for 3 seconds at 150 psi
- Customer Expectations
- Decrease entire process time from 1 minute to 30 seconds
- Eliminate ergonomic and safety issues
- Automate entire oil and bag process
- Time and pressure specifications for each nozzle type must remain the same
- Better "handling" of the parts/nozzles
- Action Items For Customer (Jim Kalinski)
- Contact information for AAT's EHS safety coordinator
- Contact information for Dave Wright (sponsor/provider of financial support) for more specific budget info
- Provide pictures of the current system if already available
- Provide access to process documentation either during visit or electronically, if available
- Provide MSDS for Brayco 460 (10W30) oil
- Provide specific pressure and duration for CFM nozzles
- Provide specs on coupler for the CFM nozzles
- Provide access to safety statistics/training documents from EHS coordinator during visit
- Provide knowledge on any attempts at using a cross thread adapter. Successes? Failures? Why?
- Double check on possibility of taking videos (perhaps capture the process in action?)
- Team Action Items
- Ask how critical automating the bagging system will be
- Include names and that everyone is a citizen
- Verification of dimensions of existing system
- Expectations of Plant Visit
- Witness Oil and bag process being executed (shadow the operators)
- Speak with more oil/bag operators (?)
AAT, LLC Plant Visit [9/2/14]
Operator Information: Elaine
- Approx. height 5’6’’ with medium sized hands
- Complained of back, shoulder, and neck pain after working all day
- Processes approx. 140 Pieces in 3 Hours,
- Relatively new employee (most working on this task are new)
- received no formal ergonomic training
- reads nozzle prints to find appropriate information and pressure/time setpoints
- Stands on safety mats at machine and work station,
- required PPE: Plastic Gloves, Safety Glasses, and (if available) Plastic Aprons
Existing Nozzle Oil and Bagging Process
1. Place one row of parts onto mat on top machine surface (approx 14-16 nozzles).
2. Find specific coupler to attach CFM nozzle to fixture.
3. Attach coupler to first nozzle.
4. Place nozzle in machine.
5. Tighten pressure relief valve.
6. Set pressure and duration on machine.
7. Run machine a few times until proper pressure is reached (150 PSI for CFM56).
8. Machine runs for 5 seconds for CFM56.
9. Green light turns on when machine is on.
10. When green light shuts off, part ready for removal and operator opens the hood door.
11. The relief valve is loosened to let some pressure bleed out before removing the nozzle from fixture.
12. Nozzle is removed and set on work bench to dry.
- NOTE: CFM nozzle does not require a specific draining time before being bagged. Nozzles all sit for a different amount of time on the workbench. Nozzles may drain different amounts, does this affect the nozzle while in storage?
13. Parts wait on work bench until the operator completes all parts in that row
14. Operator finds and attaches specific CFM plugs/caps to the nozzle.
15. Operator places nozzle into plastic bag.
16. Operator twists bag shut and tucks the excess bag under the nozzle and places it on a rack.
17. Nozzles are delivered to AAT shipping department.
Current Tester Machine
- 2 Power Sources:
- Shop Air
- 480 Three Phase Voltage
- Older Machine from GE (approx 20 years old)
- Has many capabilities that AAT does not currently use
- Must bleed off pressure before removing nozzle so that part doesn't potentially fly off and damage system and/or part itself
- While ability to run without timer exists, all operators now use timer
- Safety on door hinge that triggers machine to shut
- When door is opened there is a lot of oil mist emitted into the air
- Machine is lined with foam to help with atomized oil buildup (return oil to liquid phase)
- Machine must be refilled with oil once a week
(Approx. 10 gallons)
- Operator fills oil reservoir using a 5 gallon bucket
- Current scale is analog. Digital would be preferred.
- Large red power switch on the right side (Pump on/off switch)
Safety Coordinator: Doug Daeffler
- No recorded incidents, however some complaints of back problems have been filed
- Machine ergonomic issues was rated by Humantech, Inc
as low priority
- Has operators rotate between jobs to avoid injury on Oil and bag machine (preemptive measure)
- AAT uses Humantech safety program and used the BRIEF Survey (Baseline Risk Identification of Ergonomic Factors)
- There is no specific safety training for oil and bag operators
Action Items for Customer, Jim Kalinski
- Send approved pictures & videos from MSD team's time at AAT
- Documentation/prints/notes of oil/bag process specifications, setpoints, etc.
- CFM56 nozzle specifications (?)
- Brayco 460 10W30 Material Safety Data Sheet
- More specific information on existing pump
- MSD Team CAN redesign oil flow system. We do not have to use existing pump/tubing/etc
- Automation of oil flow system is priority over automation of bagging system - confirmed by J. Kalinski
AAT, LLC Plant Visit [9/22/14]Attendees: Alex, Mischa, Ericka
AAT Correspondent: Carl Waterman
- CFM Nozzle Procedure
- Set Preservation Stand Pressure to 150 psig
- Connect fitting to cover inlet of nozzle and attach to the preservation line
- Place in tank and close the cover
- Activate the switch and allow oil to flow for five seconds
- Turn off the flow and open the bleed to remove pressure. Close the bleed.
- Disassemble and allow the excess oil to drain. Cap the nozzle ends and place in the bag.
- Range for the Couplers
- 3/8 - 24
- 7/16 - 20 * Most Common
- 1/20 - 20
- 9/16 - 18
- O-Ring Size (Inside Coupler)
- Misc. Notes
- Filter change (1x/month)
- Filter inside the tank can be cleaned (1x/month)
- O-Ring is changed as needed to due normal wear and tear
MSD I & II. Maintain a record of team/guide meetings. This includes discussion, action items, decisions made, and work assigned.
Conference Call with Jim Kalinski [10/13/14]
- Kesh, Dan, and Alex conducted a conference call with
Jim Kalinksi to bring him up to speed with project, as he
was not able to attend the Week 6 Design Review.
- Conference Call Outcomes:
- Nozzle plans can be obtained, usually 30 days notice necessary. Jim can override this
- Items up to $300.00 can be ordered from MSC, Fastenal, and Granger immediately
- MSD team to set up conference call with AAT Controls Contractor
- Leak in MSD's scrap nozzle drops pressure by about 10psi (to ship, pressure cannot drop more than 3psi)
- Conference Call Outcomes:
Intellectual Property Considerations
- AAT Quality dictates what materials and documentation Jim is allowed to share with the MSD group.
- All nozzle drawings, models, and AAT parts belong to Parker Aerospace/GE Aviation.
- Peer reviews are conducted by all members of the team
for each member of the team. These reviews are conducted
on a weekly basis (by Friday of each week). The team's
norms and values are a basis for how we grade each
Team Values and Norms, 9/5/2014
Team Values and Norms
Refer to Team Values and Norms page for more information.