Stained Glass Mosaic Production

1. Stained Glass Mosaic Production Blue Barracudas Sean Eagan BeccaWhelchel Marc McDonald Thomas Spurlock Will Stump Nasser Ali

2. What are our goals? • Create an efficient production system • Apply principles learned in IE 200 & 220 • Work as a team

3. Production Overview • 3 different types of glass must be cut into different shapes to form a flying WV symbol • The pieces of glass are glued onto a piece of plywood • Grout the entire mosaic • Refine product and adhere felt backing

4. Work Assignments *Time was calculated using the MOST method

5. Initial Problem Improvement • The grinding process took far too much time • Nipped glass would scatter as it was cut • Gluing the white glass took far too much time moving one at a time • Determining which face of the glass should face up took too much time, and was often inaccurate • Cutting glass is the longest and most difficult process • Cuts were made more carefully, and cutters improved their cutting skills • A box was used so the scattered glass could be quickly recovered • Glue was applied to a wide area and many white squares were glued at the same time • The dull side was marked so it could be easily identified • More people would be set on this task

6. Initial Problem Improvement • Whole mosaics would take longer to make if each glass cutter cut each piece • Often too much glass was nipped • Loose cut glass pieces were often confused, or misplaced causing recutting • The cutters were assigned various different pieces to specialize and cut so the gluers could pull the pieces and complete the mosaics. • Gluers would pull the various pieces from the nipper as they needed them, acting as a kanban, freeing a worker to do other jobs that required more attention • A labeled board was set up to allow quick identification of the various pieces

7. Workspace Layoutand Spaghetti Diagram

8. Quality Control • Grind poorly cut blue pieces • Use template to nip yellow glass and tesserae into same-size pieces • Use no more or no less glue than needed • Carefully monitor grouting process • Remove excess grout

9. Safety Practices • Goggles must always be worn to protect eyes from glass • Water must always be in the grinding machine, to prevent overheating • Cutter and nipper operators must be trained with the tools • Glass should be nipped down, and away from faces and other persons

10. Cost Analysis – Overhead Costs

11. Cost Analysis – Material Costs *Assuming no step has to be redone, which is improbable

12. Cost Analysis - Labor

13. Cost Analysis • *Assuming all 1000 units are sold

14. What We Learned • How to create an effective and efficient production system • How to work as a group and solve problems together • How to IE 200 and 220 principles apply to real systems