Fabric Shredding Process and Facility Design

Project Launch

Week 0

Problem Definition

Week 3

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Future (MSD II)

Future (MSD II)

Project Launch

Week 0

Problem Definition

Week 3

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Major Points:

- Met with team- Developed norms and values- Understood Project Readiness

Packet- Built relationship with

customer

Project Launch

Bottom-line: Researched topic and gathered a basic understanding on the project and deliverables.

Learning Points:

- Research- Shredding process - Existing

systems/companies- Brainstorm/develop

milestones

Takeaways:

- Developed:- Problem statement- Stakeholders- Customer questions

Project Launch

Week 0

Problem Definition

Week 3

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Future (MSD II)

Major Points:

- Preliminary Schedule- Scope defined- Engineering Requirement

introduction- Work Breakdown Structure

Meeting Powerpoint

Meeting Notes

Problem Definition

Learning Points:

- George Mason will have some insight onto final product to be produced

- Further research into the shredding process needed

Takeaways:

- Scope defined as a complete production line per George Mason's recommendation

- Change needed to Engineering Requirements

- Rochester based location- ROI stated as 5 years or less

with the goal of >=$0.32 per pound

Bottom-line: Further research into the details of the process and machinery is required

Project Launch

Week 0

Problem Definition

Week 3

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Bottom-line: GM report doesn’t affect our research. More specific and in depth research needed.

Future (MSD II)

Major Points:

- Engineering Requirements- Functional Decomposition- Benchmarking- Risk Assessment

Learning Points:

- George Mason’s report and its impact on our scope

- Research on subsystems and possible equipment

Takeaways:

- More research needed to determine if cleaning and automated sorting machine are options

- Automated bale machine is most effective

- Space requirements needs more research

System Design

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Project Launch

Week 0

Problem Definition

Week 3

Future (MSD II)

Bottom-line: Cleaning eliminated. Research specific details and associated costs for subsystems.

Major Points:

- Finalized Engineering Requirements

- Subsystem Identification (Sorting, Shredding, Baling)

- Initial Cost Breakdown Tool

Meeting Powerpoint

Meeting Notes

Learning Points:

- Further research into subsystems is needed

- Meeting with Qian Song from Saunders College of Business

- Cost Accounting 101 with John Kaemmerlen

Takeaways:

- Cleaning step is eliminate (but space needs consideration)

- Multiple suggestions for Cost Tool

Subsystem Design

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

System Design

Week 6

Project Launch

Week 0

Problem Definition

Week 3

Future (MSD II)

Bottom-line: Project focus was narrowed. Insulation was chosen as a end product.

Major Points:

- The lack of an end product restricted progress

- Team struggled to get answers from contacts

- Developed/discussed options to move forward

Learning Points:

- Bonded Logic appeared to be the model of success

- The concept of “fluff” may be an intriguing stopping point

Takeaways:

- Insulation is a viable path to pursue

- Keeping flexibility in the system is still a priority

Emergency Meeting

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Subsystem Design

Week 9

System Design

Week 6

Project Launch

Week 0

Problem Definition

Week 3

Future (MSD II)

Evolution of the Cost Tool:

- Basic model with user inputs page- Library functionality- Overall Cost Tool (Future - Slide 17)

Cost Analysis

Bottom-line: Create a robust tool to guide machine selection and evaluate project costs

Takeaways:

- Remove financing option and replace with depreciation model

- Prioritized list of tasks to complete- Include more visual aids (Graphs and/or

Charts)- Create a more user friendly interface

Today

Week 15

Cost Analysis

Week 12

Emergency Meeting

Week 11

Subsystem Design

Week 9

System Design

Week 6

Project Launch

Week 0

Problem Definition

Week 3

Future (MSD II)

Insulation as an End Product:

- Overall Process Chart for Insulation- Potential Value Streams- Recommended Sorting - Discuss Plans for MSD II

Today

Bottom-line: Update with most current information since Emergency Meeting in week 11

Insulation Process

Receiving Sorting1. Whole

garments2. Jeans3. % Cotton4. None

Cutting1. Rags

2. Clippings

Shredding1. Fibers2. Various

shredded sizes

Remanufactured Product*By this point in the process, the product could be sold as raw material or remanufactured

Baling*Required step for nearly all sold products

Mixing1. Fibers

2. Various shredded sizes

*Same as “shredding” just a better consistency

Cording1. Fibers

2. Various shredded sizes

*First step in making any additional products

Potential Sellable Items at Each Step

Project Launch

Week 0

Problem Definition

Week 3

System Design

Week 6

Subsystem Design

Week 9

Today

Week 15

Emergency Meeting

Week 11

Cost Analysis

Week 12

Future (MSD II)

MSD IIWhat would ‘WOW’ you?

Overall Goals1. Simulation2. CAD Layout3. Cost Tool4. Final Report

Concluding May 7th, 2015

Simulation

Vision

1. A 3D animation depicting the shredding facility

2. Flow of textile, people and equipment in the facility

BenefitsA Simulation will help determine:

- Throughput- WIP- Staffing per shift- Downtime / Waiting time- Will allow calculations for more

accurate ROI

Next Steps

- Quickly evaluate alternatives- Takes variation of machinery and people into account- Predicts line performance- Reduce risk- Maximize impact of the investment

Facility Layout

VisionAn layout showing:

1. Machine footprint2. Empty space3. Space utilization4. Flow of raw material, people, and

finished goods5. Drops for electricity/air/other

Benefits

- Determined machine location- Visual of flow through facility - Distances between stations - Where everything is located in

relation to the other - How much space is required for

necessary processes

Next Steps

- Identify machine footprint requirements- Power drops- Computer stations- Scrap bins

- Create size categories to add options to layout- Identify material handling system- Create starting layout of each size category- Possibly test with cardboard placeholders

Cost Tool

VisionA user friendly tool with 5 tabs, each having specific functionality

1. User Instructions Tab2. Machine Library Tab3. Machine Selection4. Overall Cost 5. Background Tab

Benefits

- Complete hand-off- Easily adjustable- Comparison tool- Machine recommendations for

future analysis- Maximum flexibility

Next Steps

- Add new machines that we identified as part of the process- Carding Machine- Mixing Machine

- Make the tool more robust- Add more costs (Ex: Transportation)- Implement depreciation function - Add graphs of important metrics

- Update the User instructions

Final Report

VisionThe final report will contain:

1. Abstract2. Summary of Phases3. Results & Discussion4. References

Benefits

- Organizes all project information into one place

- Ensures Goodwill understand where information came from / was calculated

- Will provide Goodwill a start for future business cases

Next Steps

- Watch as the project develops- Keep this as a continuous project activity- As pieces of the project move forward, this report will be updated

Gantt chart of MSD II - SSimulation

- Identify process/line -Obtain specifications and constraints - Final simulation -Analysis

AutoCAD- Identify machine layout requirements -Select conveyance system- Basic layout -Final layout

Cost Tool- Identify all machines -Add in depreciation functionality and finish library component- Finalize Cost Tool -Add Graphs of important data/metrics- Complete user instruction tab

Final report- Meeting to determine what to include in paper- Finalize paper

Executive Summary- Identify key components to include from report- Finish summary

Questions?