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Design Approach Method

I 2.1 – Reduction in Vehicle Paint Rework

Victoria Arauz, Bryce Jimenez, Jose E Ramos, Isaac Salas

Ingram School of Engineering

Step 1. Identify the Problem

Step 3: Set a Target

Step 4: Cause Analysis

Step 7: Data Collection

Step 2: Break Down the Problem

Ultimate Goal: Reduce the rework cost associated with

an inadequate cleaning process of the assist jigs used to

hold open the tailgates and hoods of Toyota trucks in an

ergonomically safe manner.

Current Situation: In efforts to clean assist jigs, team

members are holding the jig on a vibrating surface and

slamming it against an anvil. The process is creating

quality defects as debris is transferred from the jigs to

the vehicle during the painting process.

Acknowledgements

Team Members

We would like to thank the following individuals for

their help on our project:

Mr. Julio Mata – Assistant Manager - Paint Engineering

Mr. Bill Harloe – Paint Quality Engineer

Mr. Roland Garcia – Maclellan Engineer

Toyota Kaizen Team

Dr. Patrick Thomas – Texas State University

Toyota’s 8 Step Process is used to break down, organize and

remove all waste in the process.

Step 6: See Counter Measures Through

1. Redesign the cleaning process to reduce the transfer

of debris which will reduce rework cost.

2. Improve the ergonomics of the cleaning operation.

3. Improve or maintain cycle times.

Brush Design

Exercise Jig DesignAir Pressure Design

Step 7: Data Analysis

1. Jig will be clamped into tray.

2. Tray will slide into chamber.

3. Blast with high air pressure

to remove zinc pellets.

4. Vacuum at the bottom to keep

area clean of zinc.

1. Clamp jig into tray.

2. Slide into chamber.

3. Vibrating gun on the side

will exercise jig coil to

remove zinc.

4. Vacuum at the bottom to

keep area clean of zinc.

1. Clamp jig on to

360 degree rotating

table.

2. Brush attached to drill

bit will then vibrate

between coil.

3. Debris collected by

trash bin.

Problem 2:

Assist Tailgate Jig

Assist Hood Jig

Current Problems:Problem 1:

Process is physically demanding

TM slams jig on anvil and

withstands vibration

To remove zinc pellets from jig

To clean jig

To avoid paint defects

Workers cycling out

quickly

Increase in number of defects near

hood and tailgate

Zinc pellets are falling on surface

Coil on jig contains left over

zinc

Zinc machine removes paint but

leaves debris

Insufficient process to clean jig

Increase in rework

cost

Step 5: Create Countermeasures

Step 8: Recommendations

CAD Simulation

Phase 1

Phase 2

First Design

Phase 1 Data:

Determined which combination of

cleaning mechanisms worked best.

Uncontrolled

variables:

1. Amount of zinc

in coil was

inconsistent and

varied per jig.

2. Deformed jig.

3. Zinc debris

collection.

Cycle Time:

Rework Savings:

Ergonomic Improvement:

Take away from Phase 1:

Evolution of Design

The Four Stages

• Improve ease of the jig's installation.

• Replicate the design to fit multiple jigs.

• Use Digital Twin to quantify ergonomic

improvements.

• Design enclosure around fixture.

• Funnel underneath enclosure to collect zinc debris.

• Evaluate Heijunka “Leveling”.

· Investment: $10,000

· Payback Period: 0.21 years

· Cost Reduction: $47,000

Insufficient or unnecessary

· ROI includes repair materials,

overtime for defects related to

improper cleaning, and

reduction in medical claim rate.

Optimal region