Subsystems Design ReviewNathan Arrowsmith, Samantha Reinhart, Rachel Short, Yelena

Tuzikova

Concept Selection - RevisitedArrange by Part Family with Flow

Racks

Arrange by Kits

Arrange by Part Number with

Bins

Arrange by Assembly

Sequence with Bins

Arrange byMachine

Arrange by kits in U-shaped cell

Underlying Principles

- Replenishment and retrieval is compartmentalized- Parts can still largely be placed near POU/corresponding machines

-Minimal inventory in cells-Inventory accuracy

-Locating parts is as easy as counting-Easy for new employees and water spider

-Minimize motion waste in cell/bins easily accessible-Improved cycle time of assembly

-Ergonomic-Minimize motion within the cell

-Easy replenishment-Visual management-Minimal inventory in cells-Inventory accuracy

Cons - Mixed use parts can end up far from POU

-Kits need set-up

- Parts are rarely at POU-Movement waste

-Need parts in multiple assemblies

-Extra tabletop storage needed to be ergonomic

-Kits need set-up

Constraints -Flow racks require structural changes that might reduce space inside cell

-No central storage

-Employee approval

-Inadequate space at assembly location

-Not enough space around machine to store all components

-Would need to rearrange / re-layout cell-No central storage

Cell OverheadTwo Aisles

Left: Aisle 1Main assemblyPOU Storage

Right: Aisle 2RepackKitting

Overflow Storage

Aisle 1Left

Right

Aisle 2Left

Right

Underutilized Space in 922A

Aisle 2 has the most under-usedspace.

Note: Most of the space in redis dedicated to repack.

Repack materials arrive so inter-mittently that we assumed thatthis was flex space until Jenclarified its use.

Material Presentation RulesVisual:1. Fabricated and Purchased items will be kept in yellow bins with yellow or

white labels. 2. VMI items in another color bin (purple?)3. Electronics stored in black bins4. Purple card placed inside bin when the kanban card is removed and the

part is on the ordered item list5. Shared part storage must be labeled with name of primary/owner cell6. Bin locations must be labeled as well as the bins

Storage:7. Store one days worth of corrugated and VMI inside the cell8. Dedicated storage for overstock including one big bin for fabricated

overstock parts9. Flexible location for infrequently used parts10.General rules for highest usage parts

Part Storage Rule Ideas Only Kanban items are included so far - working on obtaining order quantity informationThese parts require a total volume of ~21 cubic feet

1. Categorize items by unit volume x (2 Kanbans - 1 unit) into S, M, L, and XL amount of bin storage needed

2. Dial and rod parts will have non-bin storage, not based on volume

Category Storage Volume (in^3)

Count

S <0.5 23

M <10 44

L <100 48

XL >100 28

Dial N/A 30

Rod N/A 17

Test Plans and Metrics to Verify Design

Test Plans

Kitting components for a day’s worth of work❖ Operator kits own parts from a ‘central location,’ only takes what needs for ‘x’ number

of jobs that day. Assembles in cell.❖ Persons needed: Jen, Team

Arrange parts by machine

Arrange parts by assembly sequence❖ Search for VMI parts in current state, and then after our rules are implemented❖ Given an assembly BOM; how long to find parts?❖ What Kanban cards have been turned in? How many steps do they take?❖ How close is this parts Kanban size to the actual given number of parts on hand?❖ Persons needed: Jen and/or Kurt, Team

Alternative Cell layouts❖ Single aisle “U-shape”❖ “U-shape” cell with flow rack at front

Metrics Measured

❖ Time spent looking for parts

❖ How many times a day is a part needed that they don’t have a Kanban card for

❖ Inventory Accuracy (may be difficult to measure- how closely does reality match system?)

❖ Distance travelled: Spaghetti diagrams

Project Plan