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.
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
Designs and Flowcharts
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.
Layout and Spaghetti Diagram
Time Studies and Current Analysis
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.
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.
2. Dial Operation
Risk AssessmentThe risk list for this phase has been updated with four additional risks. In addition, the risks with the greatest severity have been highlighted.
Design Review Materials
The Design Review for this phase will consist of the following:
- Problem Statement
- Engineering/Customer Requirements Review
- Functional Analysis
- Morphological Chart
- Concept Selection
- System Architecture
- Engineering Checklist
- Time Studies
- Process Flow Charts
- Spaghetti Diagrams
- System Level Proposal
- Risk Assessment Update
- Project Plan
The full Systems Review Presentation can be accessed here.
Plans for next phase
- As a team, where do you want to be at your next review? What questions will you answer during the next phase?
- As an individual on the team, what are you doing to help your team achieve this vision? (Use the individual 3-week plan template for this).