Preliminary Detailed Design
Team Vision for Preliminary Detailed Design Phase
• Plan for this phase: What we actually completed.
• We wanted to meet with subject matter experts: We met with IISE to gain insight and experts’ opinions.
• We wanted to redefine problem statement: We met with customer to ensure new problem statement was relevant and what she was wanted to see out of this project.
• We wanted to classify inventory into 17 categories: We received approval on 17 categories. We further classified what food types go into what category and created visual for the volunteers.
• We wanted to establish an experiment: We prepared the procedure. We received approval from our customer.
• We wanted to run the experiment: We formed instructions and had our customer send out work instructions to employees. We gathered supplies and created a board to be used to conduct the experiment.
• We wanted to gather experimental data on effectiveness of the board, as well as seeing the employees’ level of participation and willingness to utilize and inventory management system: We conducted a week-long experiment. We conducted twice-daily checks.
• We wanted to create a BOM for potential purchases: We researched potential items and the costs associated.
• We wanted to form test plans: We completed half of the test plans for the engineering requirements.
• We wanted to continue to update risks: We continued to update risks as new problems arose.
The team track progress using Trello where we are able to assign ownership to various tasks. Trello is also able to track what has been completed and what will need to be completed in the future. The second part of each statement above shows the progress that was made during this phase.
Prototyping, Engineering Analysis, Simulation
When it comes to what should the team choose to tackle first out of experiments, engineering analysis, and simulation, the choice seemed to be easy. Experiments were chosen to be the first tool utilized because as an industrial engineering team who wants to utilize lean principles, performing small experiments seemed to be the logical thing to do. This comes from one of lean’s key principles being: make constant small changes as soon as possible to understand what works and what doesn’t. Furthermore, experimentation needed to be done for this project because the task is to improve an inventory management system. With this in mind, it will be critical to make sure that the right system is in place when the team leaves. So running multiple experiments in order to dial in on what the right system is, seems logical.
Feasibility: Prototyping, Analysis, Simulation
During the Preliminary Detailed Design phase, we completed an experiment to test the feasibility of our replenishment board idea.
After a successful experiment, the results can be seen below.
Drawings, Schematics, Flow Charts, Simulations
Categories: Our team went through all the inventory at FoodShare and generated these 17 categories. We then reviewed with our customer, Sharon, and got approval. Moving forward these 17 categories will supply Sharon with the knowledge of what items need replenishment, so she can reach out to the public and ask for donations.
Digital Inventory Management Interface: We designed an easy to use interface which will be the input for the digital inventory management system. Employees will utilize this interface to assist with inventory management. Below is a prototype which is currently in development.
Digital Replenishment Board: Using the 17 categories, we designed a digital replenishment board. The boards tracks current inventory and the red/green indicator shows if the current stock is below the re-order point.
Physical Replenishment Board: This is an actual picture of the replenishment board we implemented on 10/31. This is meant to help facilitate the experiment, and see if the replenishment board idea will work. We selected 5 categories where we had an idea of the status of the replenishment so we could check the accuracy. We also attached a statement from the team explaining the experiment and a simple flowchart for instructions. A green card means the current stock for that category is above 0, a red card means current stock is 0.
Bill of Material (BOM)
Currently our team has not purchased anything up to this point. Potential purchases may include:
- Bins needed for the 2 bin kanban system
- New shelves that will not bow
- Scanner used in for barcode reading
- Wood and Paint for a new sign
- Whiteboard to hold magnetic clips
- Camera to monitor the replenishment board
- Potential cloud system for inventory management
After doing initial research none of these potential purchases would put us over budget. However, the team will continue to monitor while moving forward.
We have formed test plans which will verify that we are meeting the ideal targets specified by the Engineering Requirements.
Below is a list of test plans we have prepared.
Below is a test plan that will verify the percentage of tasks with step by step instructions is 100 percent.
Click HERE to download the test plans document.
Below is a few examples of risks that have been added during this phase.
For a complete list of risks which we have compiled thus far, please visit: Risk Management
Design Review Materials
We will be presenting a power point presentation at our upcoming design review. Click HERE to download the power point.