P18718: ISE Utility Infielders
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Systems Design

Team Vision for System-Level Design Phase

Our team plans to accomplish as much data collection at the Kodak facility as possible. This includes conducting time studies, recording changeovers, and identifying wastes.

We have so far been able to record changeovers of all three operations at least once. We have also began to time study processes and start documentation of the processes.

Functional Analysis

Functional Analysis Chart

Functional Analysis Chart

Benchmarking

Benchmarking Information

Benchmarking Information

Concept Selection

The concept our group has selected to base our project on are the “Golden Rules of Setup Reduction” in any process.

1. Shift Internal Elements to External

2. Eliminate, Simplify, Automate - Only in that order

3. One way, the Right way, the Same way - Every time

4. Build the required level of precision into the system, not the setup

(Thomas F. Warda, 2004)

Systems Architecture and Fishbone Diagram

Systems Architecture

Systems Architecture

Systems Architecture

Fishbone Diagram

Fishbone Diagram

Fishbone Diagram

Designs and Flowcharts

Purpose

This is an example of a style of flow charts we have created in order to provide an additional visual tool to follow the primary processes in the department.

Dial Operation Process Flow Chart

Dial Operation Process Flow Chart

Layout and Spaghetti Diagram

Layout of the 3P Packaging Line

Layout of the 3P Packaging Line

Spaghetti Diagram of the 3P Packaging Line Changeover

Spaghetti Diagram of the 3P Packaging Line Changeover

Time Studies and Current Analysis

Time Studies

1. Packaging Operation

During this phase, we captured the changeover with video. The following time study was taken for the Packaging Operation in the 135 area using the video footage and breaking down the operation into steps. The full time study can be accessed here.

Partial Visual Time Study

Partial Visual Time Study

Current Analysis

1. Packaging Operation

Following the time study, we created a Pareto Chart of the steps during the changeover in the Packaging area. As depicted in the Pareto, the first 3 steps (Connect Electronics, Move 3P Machine into Place and Move In-Use 3P Machine out of Packaging Area) account for nearly 40% of the total time for the packaging operation changeover. These steps will be good candidates for future analysis and eliminating waste from the process.

Pareto Chart for Packaging Changeover 1

Pareto Chart for Packaging Changeover 1

2. Dial Operation

Pareto Chart for Dial Changeover 1

Pareto Chart for Dial Changeover 1

Risk Assessment

The risk list for this phase has been updated with four additional risks. In addition, the risks with the greatest severity have been highlighted.
Updated Risk list

Updated Risk list

Design Review Materials

The Design Review for this phase will consist of the following:

Background

System Analysis

Engineering Update

Other Updates

The full Systems Review Presentation can be accessed here.

Plans for next phase


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