P18725: L3 Team FEPSI
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

Current State Analysis

Current State VSM

Current State VSM

Receiving Current State Work Flow Diagram

Receiving Current State Work Flow Diagram

Inspection Current State Work Flow Diagram

Inspection Current State Work Flow Diagram

Kitting Current State Work Flow Diagram

Kitting Current State Work Flow Diagram

Kitting Current State Spaghetti Diagram

Kitting Current State Spaghetti Diagram

Purchasing and Scheduling Current State Work Flow Diagram

Purchasing and Scheduling Current State Work Flow Diagram

System Architecture

System Architecture

System Architecture

Benchmarking

Raymond

Brandon and Leigh took a trip to Raymond on October 9, 2017. Raymond is a forklift manufacturer in Binghamton, NY. Raymond utilizes the Toyota Production System throughout the plant. The main takeaways from the visit were:

Qualitrol

Chris interviewed Maddy Lockwood, a 4th year student who co-oped at Qualitrol. Qualitrol is a company in Fairport, NY that creates and maintains large scale power systems.

Future Benchmarking

The team plans to visit the following companies for further benchmarking:

Morphological Chart and Solutions Tables

Morphological Chart Receiving

Morphological Chart Receiving

Morphological Chart Kitting

Morphological Chart Kitting

Morphological Chart Purchasing and Scheduling

Morphological Chart Purchasing and Scheduling

Solutions Table

Solutions Table

System Design

Standard, defined flow

Future State
Future State VSM

Future State VSM

Future State Receiving Work Flow Diagram

Future State Receiving Work Flow Diagram

Future State Receiving Spaghetti Diagram

Future State Receiving Spaghetti Diagram

Future State Inspection Work Flow Diagram

Future State Inspection Work Flow Diagram

Future State Inspection Spaghetti Diagram

Future State Inspection Spaghetti Diagram

Future State Kitting Work Flow Diagram

Future State Kitting Work Flow Diagram

Future State Kitting Spaghetti Diagram

Future State Kitting Spaghetti Diagram

Future State Scheduling Work Flow Diagram

Future State Scheduling Work Flow Diagram

Future State Purchasing Work Flow Diagram

Future State Purchasing Work Flow Diagram

Standard Work
Standard Work Cover Sheet

Standard Work Cover Sheet

Standard Work Sheet

Standard Work Sheet

Standard Kit Set Up Sketch

Standard Kit Set Up Sketch

Signal System

Goal of system is to have a way to track inventory throughout the system (purchasing, receiving, inspection/test, kitting)

System will:

Reason for system:

Continuous Improvement Program

Suggestion Box
Suggestion Box Process

Suggestion Box Process

Employee Survey
Sample Employee Survey

Sample Employee Survey

KPI/Metric Tracking

The following outline will be used to set up the program:

  1. Selection of at least 1 metric in each area to track (Kitting, receiving, inspection/test, purchasing, scheduling)
  2. Add 1 metric each quarter until department tracks all five metric categories (safety, quality, human development, cost, time)
  3. Create PCBs to visually track metrics
  4. Gemba walks for visibility to PCBs (managers)
  5. Daily meeting on the floor → daily tiered huddles for problem escalation (department, managers, VPs)
  6. Review of how PCB process is going after 3mo, 6mo, 1 yr

Feasibility

The main feasibility questions the team explored during this phase were:
  1. Will the created system(s) work with the VLM within the timeframe?
  2. Will there be employee buy in with the created system(s)?

In order to address these questions, the following plans were created to ensure feasibility of the system.

Standard, Defined Flow

Standard work
Implementation plan (Effective in timeframe)
Kanban system

Continuous Improvement Program

KPI/Metric Development

Risk Table

Phase 2 Risk Table

Phase 2 Risk Table

Plans for Phase 3

Phase 3 Plan

Phase 3 Plan

Leigh Bechet's individual plan for phase 3 can be found here

Chris Lieb's individual plan for phase 3 can be found here

Brandon Hickey's individual plan for phase 3 can be found here

Jess Strickland's individual plan for phase 3 can be found here

Design Review Materials

A copy of the design review presentation can be found here

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