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Terumo Cardiovascular Systems: Oxygenator Production Improvement. University of Delaware’s Senior Design Team: Tom Craig Mike Giuliano Ronit Lilu Chase Ross Kate Staley. Description of Project. Project Goals:

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terumo cardiovascular systems oxygenator production improvement

Terumo Cardiovascular Systems:Oxygenator Production Improvement

University of Delaware’s Senior Design Team:

Tom Craig

Mike Giuliano

RonitLilu

Chase Ross

Kate Staley

description of project
Description of Project
  • Project Goals:
    • Improve the efficiency of Reservoir Assembly production line via reduction in downtime, change over time, and cycle time.
    • Employ lean manufacturing techniques from the ground up such as participation in a Kaizen event
assembly line
Assembly Line

Reservoir Inspection

Lid Assembly

VR Station

CR Station

Leak Tester

VR

CR

Lid

Final Assembly

Lid Line

Jig

current floor layout vs future floor layout
Current Floor Layout vs. Future Floor Layout

Reservoir Assembly Table

CR

VR

Lid Line Assembly Table

Product Flow

lean manufacturing techniques
Lean Manufacturing Techniques
  • The Kaizen event:
      • Attended a meeting with representation from operators, manufacturing, production supervisors, engineering, and plant leadership to discuss improvements
  • Time study
  • Spaghetti diagrams
  • Value Stream Mapping (VSM)
    • Value Added, Non-Value Added Time
customers wants
Customers & Wants
  • Customers: Terumo Management, Terumo’s Floor Staff, Surgeons, Hospitals, Patients
current floor layout vs future floor layout1
Current Floor Layout vs. Future Floor Layout

Product Flow

Reservoir Assembly Table

1 Pass of 3 Steps

6 Passes of 3 Steps Each

CR

VR

Lid Line Assembly Table

  • VR walking distance/day ≈ 6.6 miles
  • CR walking distance/day ≈ 1.5 miles
  • VR walking distance/day ≈ .5 miles
  • CR walking distance/day ≈ 0.3 miles
vr current state vs future
VR: Current State vs. Future

Current State

Future State

Time Saved: mostly due to table redesign and offline production

Walking Time - 6.3 seconds

vr concepts
VR Concepts
  • Rotate lid assembly table and align it with Chemical Table
  • Redesign Chemical Table and “L” it with the assembly line
  • Design and manufacture additional jig
  • Take wings off jigs on table
  • Sensors on bins to force order
cr current state vs future state
CR: Current State vs. Future State

Current State

Future State

Time Saved: 9.9 seconds reduced time through elimination of walking (moving caps) and addition of the chemical sensor.

Note: Increased VA time due to addition of inspection tasks

cr concepts
CR Concepts
  • Move caps down to reservoir inspection
  • Time sensor for chemical dipping
  • Move CR cart closer to operator
  • Increase inspection duties
reservoir inspection current state vs future state
Reservoir Inspection: Current State vs. Future State

Current State

Future State

Reduction in Inspection Duties

Line Balancing: Additional responsibilities (placement of 6 more caps)

proposed floor layout
Proposed Floor Layout

Table at CR Station

Table at VR Station

final vr table
Final VR Table

Tricots

Drainage cages

Fume hood

Small tubes

Large tubes

Jig

Position forcing tray

preparation before implementing
Preparation before Implementing
  • Risk Analysis
    • Met with a team of Terumo associates including engineering, upper management, quality manager, and manufacturing associates to assess risk via a Terumo Risk Analysis template.
    • Given GREENlight to go ahead
  • Update Standard Operating Procedures
    • Drafted changes to the SOP via text and pictures which was then reviewed and approved by Terumo
implementation testing
Implementation/Testing
  • Off-line implementation
    • Operator at Terumo tested the new set-up of VR table on manufacturing floor to make sure everything easy to reach and functions well.
implementation testing1
Implementation/Testing
  • Parts were loaded into bins to test how much they hold.
  • Improvements:
    • Tricot and drainage cage bin sizes increased to increase capacity
    • Positioning adjustments made
path forward
Path Forward
  • Terumo will manufacture the new bins for the increased capacity and new arrangement.
  • Design can then be implemented on the line.
  • Additional time studies and spaghetti diagrams are recommended once implemented on the line.
  • Sensors will be implemented at a later date by Terumo.
project cost
Project Cost

Note: Terumo will use their own Machine Shop to manufacture the jig and VR Chemical Hood. Team will use UD Machine Shop to manufacture bins.

revenue analysis
Revenue Analysis
  • 15 additional units/hour
  • 30,960 additional units/year
  • $12,384,000 additional revenue/year
  • $1,145,520 additional material cost/year
  • $11,238,480 net gain/year
project summary
Project Summary
  • Lean manufacturing techniques such as VSM used to increase efficiency of manufacturing process
  • Improved ergonomics for operators
  • Maximized space used
  • Decreased cycle time
  • $11.2 million net gain/year