DUN1 Intern End of Semester Engineering Presentation

Ash Abel August 2nd, 2012 10-11am

Introduction

• Junior in Mechanical Engineering at Clemson University

• Expected Graduation Date: August 2015

• First Rotation: Summer 2013

o 6 weeks in Industrial Engineering

o 6 weeks in Process Engineering

Industrial Engineering Work

Work Descriptions:

• Update and Propose plant and office layouts for new parts, machines, or setups

• Fix existing layouts to accurately illustrate the current state of the plant

• Perform time studies on lines with new machines

• Perform time studies on lines with updated machines and/or processes

• Analyze time studies to create proposals for change

Industrial Engineering Project: F25 CC, Front DP, Rear DP move

4

I made proposal drawings for safety mats for the F25 CC, Front Door, and Rear Door lines. I also calculated the amount of extra mats that needed to be ordered to provide a sufficiently safe environment.

F25 IP Stations with task distributionsStation 20 Station 25 Station 30 Station 40 Station 50

Initial Time: 1.29 Initial Time: 1.34 Initial Time: 1.29 Initial Time: 1.54 Initial Time: 1.47

Scan and Load 7 Red Clips GB 4 Metal Black Clips Lower IP 2 Silver Clips Upper IP  

Walking from welder to station 2 Red Clips Vent Driver 2 Clips Red Vent Passenger    

Dock 2 Red Clip Storage Option      

         

Final Time:1.73 Final Time:1.72 Final Time: 1.73 Final Time: 1.72 Final Time: 1.47

Time for each task of Station 10 (seconds)Scan and Load 0.14

Dock 0.13

7 Red Clips GB 0.25

2 Red Clips Vent Passenger 0.10

2 Red Clips Storage Option 0.05

2 Silver Clips Upper IP 0.18

4 Metal Black Clips Lower IP 0.34

2 Red Clips Vent Driver 0.08

Walking from welder to station 0.17

Industrial Engineering Project: F25 IP Station 10 Removal

5

After completing several time studies on each station involved in the assembly of F25 IP, I distributed Station 10’s workload evenly among Stations 20, 25, 30, and 40. As Figure 1 on the next page shows, the additional workload will put the line just above DAA takt time, but still well under BMW takt time.

Industrial Engineering Project: F25 IP Station 10 Removal (cont.)

6

Figure 1. Graph showing the distribution of Station 10’s tasks amongst Stations 20-40

Process Engineering Work

Work Descriptions:

• Design poka-yoke parts to streamline production

• Design parts for production to both accelerate production rate and reduce downtime

• Design template to assist in testing production parts in accordance with GM’s Engineering

Standards

• Perform push and pull tests on production parts to test welding/adhesive strength

• Perform MFU’s to quantitatively prove that new machines were running at production standards

7

Process Engineering Project: F25 IP Bird Feeder

8

I redesigned the bird feeder to be compatible with the pick by light system. This was done to ensure that screws are not dropped on the floor or into the IP. It also forces the operator to follow a specific procedure on every IP which will result in a more consistent product.

Process Engineering Project: CTS IP Flame Testing

9

Shawn Gannon and I were tasked with finding the expiration time of the CTS center stack after the flaming process. This was done to aid in the storage of the flamed parts due to a lack of room on the floor.

Introduction:

Results:

The left side of the center stack was the location where every failure occurred. Every other area passed the pull test at all times tested. This result showed that the IP’s had a longer expiration time than originally thought, and that there was a deeper issue beyond the flaming process. After further investigation, the problem was found to be coming from the lamination machine local temperatures.

Process Engineering Project: F15 Map Pocket Push Test

10

Figure 2&3. Plots of the push tests on the F15 Map Pockets to compare the former method of gluing the pocket together versus the new method that welds the pocket together.

Conclusion

Industrial:

• Collected data that enabled other IE’s to focus on its analysis

• Made layout changes that smoothed production flow

• Developed a plan to remove a station from F25 IP

Process:

• Conducted tests to ensure that our parts were compliant with customer standards

• Conducted tests that resulted in approving longer storage time for CTS IP Upper

• Designed poka-yoke parts that prevented assembly errors

• Designed pick-by-light parts that will help the product become more consistent

Thank you for your time

Questions?