Quality & Productivity Lab

1. Quality & Productivity Lab ENGR 1181

2. Auto to Food Industry! Many industries use assembly lines to get the job done quicker, cheaper, and safer. The auto industry pioneered the assembly line with Henry Ford. What other assembly line industries can we think of?

3. See here a unique assembly line!

4. Alternatively, another example of an assembly line (Henry Ford).

5. Today's Learning Objectives Manufacturing line  Assembling Potato Heads • Introduces Industrial and Systems Engineering (ISE) concepts • Simulates production and improvement process • First Run  Pull Mechanism • Second Run  Pull Mechanism • Aim to maximize profit utilizing LEAN and SIX Sigma

6. Sequential Workflow Pull System • Create product or service as they are demanded • Tended to be used on lower volume products, but note that Toyota and others have broken that paradigm • Value add occurs when demand calls for it: don’t add value until it is called for by the next step downstream • Requires more communication and coordination • Tends to better optimize flow, inventory, quality, speed, etc. Push System • Attempt to simplify by making assumptions about demand • Made for stock because demand is assumed predictable and stable • Reasonable volumes of standard products • Relatively high inventory and Work-in-Process to support build for anticipated demand • Value add is a steady push, add value, move product/service, do it again

7. Sequential Workflow (cont’d) Push vs. Pull  Fast Food vs. Sit-Down restaurants

8. Sequential Workflow (cont’d) • As you brainstorm to improve your assembly line between runs, remember: • Leanmanufacturing Increases productivity and • Six sigma reduces Variation to improvequality

9. Lean – Eliminating Waste Waiting Waiting on parts, waiting for information Transportation Any unnecessary movement of materials or Work in Process (WIP) Overproduction Producing too much or too soon Intellect Any failure to fully utilize the time and talents of people Rework/Defects Any repair, defect or rework, does not conform Motion Any motion of the worker that does not add value Inventory Any more than the minimum to get the job done Processing Over-processingProcess Variability Over Handling due to defects

10. Six Sigma – Reducing Variation Voice of Customer Weak specification of customer requirements/demands No Visible Measurement/ Management System Workers have no visibility for process performance Supplier Variation Too much, too little, poor quality, change in quality Unforeseen Events Equipment failure, accidents, absences, environmental conditions Lack of Training Workers have not been trained to do the job Paradigms/Habits People locked into a way of doing something because it’s always been done that way Lack of Standardization No Standard Operating Procedures (SOPs), no method consistency, no work standards Worker Training Worker Bad habits get passed on • ENGR 1181

11. Today’s Lab

12. Agenda

13. 4 Orders of Potato Heads Production Line Overview Teams: Customer 3 Different Mr. Potato Heads: A, B, & C

14. Sequentially, Process must flow from Operators to Final Tester (FT) to the Customer The Process • Team Roles: • 1 Operations Manager • 9 Operators • 1 Final Tester • 2 Customers • 1-2 Transporters • 2 ISE’s

15. Note : There are 4 total teams in the lab

16. Team Brutus Team Buckeye Team Gray Team Scarlet

17. Additional Notes • Transporters are the only people who can move parts amongst tables • Operators cannot leave their assigned workstations • If you don’t get an order in on time, still give it to the customer as quickly as you can

19. Production Run #1  Pull • Will get an order every minute for 4 minutes • Orders received more than 75 seconds after the order is announced will be considered late. Mr. Potato Head C Mr. Potato Head B Mr. Potato Head A

20. Improvement Cycle You will have 10 min to improve your system! Kaizen:A Japanese business philosophy of continuous improvement of working practices, personal efficiency, etc.

21. Production Run #2  PULL • Will get an order every minute for 4 minutes • Orders received more than 75 seconds after the order is announced will be considered late. Mr. Potato Head C Mr. Potato Head B Mr. Potato Head A

22. Today’s Assignment By the end of class: • Complete two runs of the Mr. Potato Head Assembly Line. • Appropriately record all data collected on the Q&P lab spreadsheet • Debrief with your team regarding push vs pull systems • Have your lab Checkout Procedure signed by a TA or your Instructor.

23. Helpful Hints • Ensure that you understand your role prior to lab time. • Introduce lean manufacturing to your overall process where applicable.

25. Important Takeaways • The push and pull systems each yield different results. • By eliminating or minimizing different forms of waste, productivity and net profitability can be greatly enhanced. • ISEs have the ability to design, analyze and oversee the operation of a system for sustained efficacy.

26. Preview of Next Lab Lab 3- Circuits Lab • Construct electric circuits using a breadboard • Learning how voltage, current and resistance are measured • Study Ohm’s Law, Power Law, Kirchhoff’s Current Law and Kirchoff’s Voltage Law • Calculate and measure the equivalent resistance of electric circuits • Understand polarity of certain electrical components