|Project Summary||Project Information|
ArcWorks provides manufacturing services including hand labeling and packaging operations. The current process for hand labeling has very stressful steps and can only be done by highly skilled workers, resulting in a slow turnover between products. Within the current process, errors in packaging lead to large time delays.
The goal of this project is to analyze the current process steps in order to make the process easier and faster while still producing a hand-labeled look. The expected result will allow for a faster method to find errors as well as reduce operator fatigue and minimize repetitive stress injuries while adhering to all OSHA guidelines. The new process will increase production and will be easier to implement and teach.
|Cassie Kaczmarek||Project Managerfirstname.lastname@example.org|
|Kyle Chrysler||Lead Process Engineeremail@example.com|
|Emily Hebert||Lead Mechanical Engineerfirstname.lastname@example.org|
|Justin Cook||Mechanical Engineeremail@example.com|
|Troy Bailey||Industrial and Systems Engineerfirstname.lastname@example.org|
- The team met with ArcWorks to determine the main project goals and deliverables. Based on these goals, lists of customer and engineering requirements were organized and prioritized. The team started to determine some of the constraints and risks to the project and how they will mitigate risks in the future phases. A timeline was outlined for the rest of the MSD I.
- The team developed a functional decomposition to determine all the inputs and outputs of the bottle wrapping process as well as a fishbone diagram. The ME’s developed concept ideas for the glue well, neckband dispenser legs and rolling tray. Ideas from these concepts were benchmarked and feasibility analysis was performed. The IE’s collected and analyzed time study data on the time it takes to label one case as well as analyzed the walking patterns of Material Handlers in the current layout. New work layout concepts were designed. Concepts from both the MEs and the IEs were selected to proceed with feasibility analysis and prototyping for the next phase.
Preliminary Detailed Design
- The ME's developed and documented specific design ideas for applying glue and the label more effectively. This included meeting with several SME's from the ME dept. We also did some simulated torque trials following a set of calculations. Test plan development also started. The IE's created some documents to begin the transition into using new methods on the floor. They also simulated layout options using tables in a classroom at RIT. Process flow and floor layout ideas were documented more specifically.
- The IE’s ran test experiments of process changes to determine feasibility and employee response. The ME’s finalized their feasibility analysis of the Glue Well and created prototypes for both the neckband dispenser legs and the rolling tray. Both the MEs and IEs furthered developing test plans and the team developed plans for MSD II.
Build and Test Prep
- We visited to review the portions of the design work completed in the Spring that they implemented during the summer. We started collected performance data to assess the productivity improvements to date. The ME's continued to work on finalizing the designs for the tray and glue well, based on discussions and on-site tests. The IE's were approached with a request to add an assessment of a problem with an ArcWorks supplier to their to-do list, which they agreed to do.
Subsystems Build and Test
- The ME's are close to done with design work for the motor box, motor coupling, gate hook, dispenser legs, and rolling tray. Work also continues on nailing down the "right" angle for the glue well. The IE's conducted the worker survey, received some useful responses, and have analyzed the results.
Integrated Systems Build and Test
- The IE's are working on standard work documents, and process improvement ideas, and they prepared for and visited the bottle printer. The ME's continue to upgrade and test designs and prototypes of the various subsystems.
Table of Contents
|MSD I & II||MSD I||MSD II|
AcknowledgementsWe would like to acknowledge the guidance of Prof. Kaemmerlen and also Ken Mihalyov.
Other Subject Matter Experts we would like to acknowledge:
- Professor Landschoot for his help on the angle calculation
- Professor Ghosh for his assistance and guidance on the angle calculation
- Professor Slack for his help on the wiring diagram and obtaining a diode
- Professor Puchades for his assistance with the wiring diagram