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Designing Products for Cellular Assembly Session CS-05

Designing Products for Cellular Assembly Session CS-05. Presented at NEPCON/Assembly East May 11, 2006 Tom Lawton ADVENT DESIGN CORPORATION Bristol, PA. Presentation Goals. Review use of Six Sigma design methodology & DMADV Review how design impacts assembly

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Designing Products for Cellular Assembly Session CS-05

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  1. Designing Products for Cellular AssemblySession CS-05 Presented at NEPCON/Assembly East May 11, 2006 Tom Lawton ADVENT DESIGN CORPORATION Bristol, PA

  2. Presentation Goals • Review use of Six Sigma design methodology & DMADV • Review how design impacts assembly • Review coordination of design development and cellular assembly • Transition to the Six Sigma DMAIC cycle • Follow a new product through the cellular design process

  3. Cellular Manufacturing Re-arranging production operations to improve flow and to reduce handling and cycle time • Group products into families • Establish the required cycle time • Review the production sequence • Design the cell layout • Adjust work to balance flow How is this done during the design process ?

  4. Define & Measure • Analyze • Concepts • Verify • Breadboard • Prototype • Design • DFMEA • Requirements The DMADV Cycle Six Sigma In Action System Design Tolerance Design Parameter Design

  5. Design for Six SigmaUse of DMADV • Define: Project Plan & ID Risks • Measure: Voice of the Customer, CustomerRequirements, Critical to Quality • Analyze: Concepts, Key Functions, Design reviews • Design: High Level Elements, Design Requirements, FMEA, Design Reviews • Verify: Drawings, BOM, PDCA, Bread board, Prototype, Implementation Plan

  6. Critical to Quality (CTQs) Convert Customer Needs into the Language of the Design Team CTQs that affect cell design… • Out of package start up reliability must be 100% • Process fluid batches must satisfy all chemistry requirements • No leaks in any fluid paths

  7. Analyze: Design & Process Concepts • Generate concepts • Combine concepts • Select concepts • Evaluate concepts

  8. Process Concepts Lead to Machine Design

  9. Design Requirements & DFMEA The Beginning of Cellular Development • Design Failure Modes & Effects Analysis • Failure modes • Consequences of failures • Causes • Controls

  10. Design Reviews • Crossfunctional teams • Team discussions • Customer participation • Engineers & assemblers

  11. Use of 3 D ModelingEasy Visualization • For Assembly • For Maintenance Access • For Interference

  12. Cell Requirements Design Development & Cellular Design in Parallel An Iterative Process Define & Measure • Analyze • Concepts Cellular Concepts • Verify • Breadboard • Prototype • Drawings & BOM • Design • Requirements • FMEA Cellular Assembly Verification Cellular Flow, Sequence, Layout

  13. Cellular Concepts Based on Design Concepts • Selection of Main Assemblies • Identification & Selection of Subassemblies Using 3D Model • Modular Assembly Concepts • Identification of complex assemblies for fixturing

  14. Basic Design Assembly Concept Electrical Assembly Front Plate Assembly Tank & Frame Supports Assemblies Subassemblies Subassemblies Waste Tank & Jet Pump Assembly Top Cover Assembly

  15. Sequence of Cellular Assembly Steps • Subassemblies & Main Assemblies Listed in Proposed Assembly Order • Includes Final Test & Packaging • Preliminary Quality Checks • Preliminary Cycle times

  16. Cellular Assembly Flow ConceptsMain & Subassemblies Tank & Frame Assemblies Subassemblies

  17. Main Assembly & Subassemblies • Cell Pack Subassembly • Cell Pack Fits to Front Plate Assembly • Front Plate Fits to Tank

  18. Shipping/Receiving Inspection/Parts Supply # 9 Mount components to power supply plate Sub # 1A Base,Fans, Line cord Cell Power Supply Sterilox Tank Assembly Traveler checkbox # 1 Start traveler & assign serial number Test Unit # 7 Inlet/Outlet Plate Assembly & Test Traveler checkbox # 2 Waste Tank/ Brine Tank / Jet Pump Assembly Traveler checkbox # 5 Assemble Salt Chute Close up & Pack # 8 Front Plate Assembly Traveler checkbox # 3 Electrical Assembly Traveler checkbox # 4 Plumbing Traveler checkbox # 4 Assemble boards to plate Peristaltic Pump Assy Build subassemblies . Preliminary Cell Work Process Flow & Sequence Sub Assembly Flow Main Assembly Flow Assemble on Carts

  19. Assembly Drawings & BOM Based on Cellular Flow • Required parts • Assembly notes • Quality requirements & checks

  20. Build pH Chamber 7756-1115 Cellular Assembly Flow & Sequence Chart Sub Assembly Flow Main Assembly Flow Build Cell Power Supply 7756-1112 Sterilox tank & sensor 7756-1107 Build Cell Pack 7756-1113 Receiving Inspection/Parts Supply Supervisor OK to ship Check Sign traveler Base,Fans, Line Cord Cell Power Supply Sterilox Tank Assembly 7756-1104 & 1128 Traveler initial box # 1 Build Outlet assembly 7756-1126 Build Inlet assembly 7756-1109 Quality Assurance Checklist Review Sign traveler Package Unit Start traveler & assign serial number Traveler initial box Inlet/Outlet Valve Assembly & Test 7756-1125 Traveler initial box # 2 Burn-In & Test Unit Add test data to traveler Front Plate Assembly 7756-1110 Traveler initial box # 3 Electrical Assembly 7756-1119 Traveler initial box # 4 Plumbing & Waste Tank / Brine Tank / Jet Pump Assembly 7756-1100 Traveler initial box # 5 Assemble Salt Chute & Top Cover Close Up & UL Test 7756-1111 Traveler initial box Labeling 7756-1102 Remote programming port 7756-1118 Tubing 7756-1129 Build Catholyte Chamber 7756-1114 Cover assembly 7756-1102 U/I assembly 7756-1124 Assemble Boards to Electric Plate Peristaltic Pump Assembly 7756-1117 Build conductivity probe 7756-1116 Brine Tank assembly 7756-1106 Jet Pump & Waste Tank assembly 7756-1108

  21. Guidelines for Lean Cell Design • Each operation is ergonomically designed • Machines are arranged in the sequence of operations needed to process the part • All operations needed to make the part in the cell and have process time < CT or Takt time • Work stations equipped with pokayokes which perform as self inspections • Aisle width is 4 ft.

  22. Preliminary Cell Layout Follows Cell Flow and Sequence Implementation Planning

  23. Questions to Ask About the Value Stream Represented by the Cell • Is the operation valuable? • Is the operation flexible? • Is the operation cycle time within takt time? • Are the operations balanced?

  24. Verify Design & Cellular Concept • Bread Board • Verify design concepts • Parameter Design of Experiments Prototypes Verify design & cell

  25. Verify BOM & Material Staging for the Cell • Lead time • Space Availability • Reduce cell assembler material handling • Level of Material Control (kanban)

  26. Verify Quality System • Final Test • Work Station Checks • Vendor Process Capabilities • Documentation Build Customer Confidence!

  27. Establish Assembler Knowledge & Training Requirements based on Cellular Design

  28. Pre-Production Cellular Assembly Flow, Sequence & Quality Chart Build pH Chamber 7756-1115 Sub Assembly Flow Main Assembly Flow Build Cell Power Supply 7756-1112 Sterilox tank & sensor 7756-1107 Build Cell Pack 7756-1113 Receiving Inspection/Parts Supply Supervisor OK to ship Check Sign traveler Workstation Quality Check incoming receipts Workstation Quality Check Base,Fans, Line Cord Cell Power Supply Sterilox Tank Assembly 7756-1104 & 1128 Traveler initial box # 1 Build Outlet assembly 7756-1126 Build Inlet assembly 7756-1109 Quality Assurance Checklist Review Sign traveler Package Unit Start traveler & assign serial number Traveler initial box CM-19-03-010 Rev A Workstation Quality Check Inlet/Outlet Valve Assembly & Test 7756-1125 Traveler initial box # 2 Workstation Quality Check Burn-In & Test Unit Add test data to traveler Label Check Final calibration & test CM-19-01-002 Rev A Front Plate Assembly 7756-1110 Traveler initial box # 3 Electrical Assembly 7756-1119 Traveler initial box # 4 Plumbing & Waste Tank / Brine Tank / Jet Pump Assembly 7756-1100 Traveler initial box # 5 Assemble Salt Chute & Top Cover Close Up & UL Test 7756-1111 Traveler initial box Workstation Quality Check Labeling 7756-1102 Assembly & Quality Checklist CM-19-03-012 Remote programming port 7756-1118 Workstation Quality Check Tubing 7756-1129 Workstation Quality Check Build Catholyte Chamber 7756-1114 Cover assembly 7756-1102 U/I assembly 7756-1124 Assemble Boards to Electric Plate Peristaltic Pump Assembly 7756-1117 Build conductivity probe 7756-1116 Brine Tank assembly 7756-1106 Jet Pump & Waste Tank assembly 7756-1108 Note: Green accepted labels will be applied to subassemblies at specified workstations when they pass the go/no-go test and inspection.

  29. Transition from DMADV to DMAICPre-Production Build & Evaluation • FMEA using Final Test Data • Service History • Compare data to determine product & cell design changes(can establish ratios) • Customer feedback

  30. Pre-Production Cell Design & Flow to Eliminate the Eight Wastes • Inventory (more than one piece flow) • Overproduction (more or sooner than needed) • Correction (inspection and rework) • Material Movement • Waiting • Motion • Non-Value Added Processing • Underutilized People

  31. Changes to Cell Design from Quality & Service DataReduce Defects & Cycle Time • Change design & method of connecting piping fittings & pressure testing to eliminate leaks & reduce cycle time • Simplified final test procedure through improved conductivity control • Simplified waste tank assembly • Vendor to supply wire harnesses

  32. Cell Requirements Product & Cellular Design Continue in Parallel Define & Measure • Analyze • Concepts DMAIC Cycle Cellular Concepts Pre-Production Cell • Verify • Breadboard • Prototype • Drawings & BOM • Design • Requirements • FMEA Cellular Assembly Verification Cellular Flow, Sequence, Layout

  33. After DMADV: the DMAIC Cycle Six Sigma In Action SDCA Define Measure & Analyze Plan-Do-Study-Act Teams Benchmark Analysis tools ID variability SDCA Employee Involvement Control Improve Plan-Do-Study-Act Design of Experiments SDCA = Standardize-Do-Check-Adjust

  34. Lessons Learned • Specify everything: fasteners, tube lengths, etc. (or the assemblers will guess) • Avoid tight fits. Watch stack up tolerances • Understand vendor capabilities • Have vendors supply complete subassemblies • Need to verify BOMs at each workstation • Have assemblers participate in prototype assembly

  35. Designing Products for Lean Cellular Assembly Methodology that maximizes value and achieves improvement in….. Customer satisfaction Operating costs Process speed(lead time) Inventory & invested capital Quality Operating flexibility

  36. Contact Information Advent Design Corporation Canal Street and Jefferson Ave. Bristol, PA 19007 www.adventdesign.com 800-959-0310 Frank Garcia, Director Engineering Services frank.garcia@adventdesign.com Thomas A. Lawton, President Tom.lawton@adventdesign.com

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