First time right - Prokon
description
Transcript of First time right - Prokon
ProKon
ProKon
Produktionsgerechte Konstruktion
(Production-Oriented Design)
First Step in First Time Right
Presented at – MTM Conference Turkey May, 2014
ProKon Analytical Method
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The term ProKon is an acronym for the German words
Produktionsgerechte Konstruktion (Production-Oriented Design)
The ProKon method is a comprehensive tool for
improving the manufacturing process, during
the design phase of product development.
ProKon Development of the Market Place
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Shorter product life cycles
Increasing number of variants
Increasing frequency of product innovations
Shorter development times
Increasingly complex development tasks
ProKon Demands on Product Development
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Greater flexibility
Quick reaction to changes in the market place
Consideration of all cost-relevant factors, at an early stage of development
ProKon Problem with Positioning a Platform
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• Large batch sizes • Ideal product mix • Reduced development expense • Reduced material costs • Short learning curve
Where is the company‘s optimum?
Customer Requirements Tailored Solution
Company Targets Standard Solution
* Prof. Dr. Ing. W. Engeln
0 % Individuality of the solution 100 %
• Single piece order • Complex product mix • Increased development expense • Increased material costs • Longer learning curve
ProKon Early Answers to Late Questions
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Time
Costs
Costs of implementing
a change
Opportunities for avoiding or
reducing costs
Concept Services Design Prototype Purchasing Department
Production/ Assembly
Sales
ProKon Optimization Potential
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0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Total costs Assembly-oriented
product design
New production
technologies
Work system and
work process
design
CIP measures Remaining costs
100%
20 - 30%
5%
10 - 20%
15%
Op
tim
iza
tio
n p
ote
nti
al in
%
ProKon MTM in the overall production cycle
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MTM Analysis Planning Production analysis
testing
optimization
quantification
familiarization
Know-how transfer
Product Development
Process Development
Production and Improvement
SOP (Start of Production)
inspection and evaluation of
ease of assembly
process capability
quality objectives
product optimization
work organization
work design
work methods
production times
clocking
possible production optimization
calculation of reference data/planning standards
MTM Process Planning Methods and tools
ProKon
continuous improvement
Ergonomics - EAWS
ProKon Definition
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ProKon is an MTM-based method for analyzing and evaluating design solutions with respect to their suitability for assembly. ProKon supports the systematic identification of possible improvements in design solutions and the quantification of the effect these solutions have on productivity.
ProKon
ProKon Ease of Assembly
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Influencing factors affecting the assembly are
defined as analyzing criteria, represented by
Basic Value
Assembly Interferences
For each of these criteria, a numerical value –
a ProKon Unit (PU) – was defined.
ProKon Advantages of the Application of ProKon
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Identification of assembly interferences at the earliest possible point of time
Quantification of the identified assembly interferences
Target-oriented reduction of the identified assembly interferences
Creation of valuable basic information for further process planning
Promotion of cross-functional communication
Avoidance of subsequent product changes
ProKon Advantages of the Methodology
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ProKon offers high analyzing speed
ProKon is easy to learn
ProKon enhances the designer’s creativity, thus supporting the creative process
ProKon
Partial project:
Number of parts:
∑ Frequency:
ProKon Units: 40 55 10 100 10 15 40 15 35 15 20 10 15 20 100 50 150 300 40
∑ Total value:
ProKon Analysis SheetNumber of partial project:
User:
Date:
Sub-assembly:
Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
∑ ProKon Units:
Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
ProKon Analysis Sheet
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Question on design Is it possible that existing components take on additional functions and, thus, reduce the number of components?
Assembly situation
Chronological order
of assembly
ProKon Value Added and Waste
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The ProKon analysis DOES NOT describe the actual assembly process.
Verschwendung
Activities analyzed with ProKon
ASSEMBLY
Value-adding activities
Non value-adding activities
Waste
• Position • Fasten • Engage • Glue together
• Distances • Waste disposal • Reading an order • Material transport
• Adjustment • Readjustment • Restrictions
ProKon Targets of Application
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Identifying and assessing weak points in the design that cause assembly interferences
Giving new impetus to the target-oriented optimization of the product design
Designing ergonomically favorable solutions
Standardizing processes (quality improvement) by establishing a uniform platform and creating modules, which can be used again
ProKon Steps in Implementing Projects
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Industrial Engineering, planning, competitive analysis, service
ProKon team: Design/development, planning, IE/MTM, supplier member of specialist department (if required)
Design/development, planning, IE/MTM, quality assurance, purchasing department, supplier member of specialist department (if required)
Yes
Create and evaluate design alternatives
Design/development, planning
Select component/sub-assembly
Supply prototype/drawing...
Assess current design
Realize optimized design
No Are the
alternatives achievable? (Process reliability,
costs, quality)
ProKon How to Proceed during the Analysis
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• In the ProKon Analysis Sheet, the assembly steps are described in the vertical and the specific assembly interferences in the horizontal direction.
• Frequencies are entered on the corresponding lines.
• The frequencies per column are summed (∑ Frequency) and multiplied by the corresponding ProKon Units …
• … yielding the individual value of ProKon Units per column (∑ Total).
• The individual values of all columns are summed to the total value (∑ ProKon Units)
The smaller the total value, the greater the suitability for manual assembly.
ProKon Steps in Analyzing the Present Design
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Present Design
Steps
1 Name the components or sub-assemblies
2 Define the assembly steps
3 Define the assembly position (x, y, z)
4 Evaluate the components or sub-assemblies with the help of the ProKon analysis sheet
ProKon Knowledge Gained
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The matrix enables the analyst to make statements regarding the components or sub-assemblies and the occurring:
Type of assembly interference and
The frequency or combination of assembly interferences
The matrix yields a total value for the complete assembly.
Every assembly interference indicates design features that have to be reviewed for possible
improvements.
ProKon Steps in Analyzing the Proposed Design
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Proposed Design
Steps
5 Question the present design
6 Optimize the design through alternative solutions
7 Reassess the modified design using the ProKon analysis sheet
ProKon Principles on Changing the Design
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Simplification of components
Simplify the geometry of components
Geometry that allows for only one positioning direction
Component that can be assembled in only one position (avoiding assembly errors and associated rework)
ProKon Principles on Changing the Design
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Support by positioning aids and available space
Positioning/centering aids, such as bevels, pivots, reliefs/marks
Positioning clearance/accessibility (ergonomics)
ProKon Principles on Changing the Design
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Simplification of directions/positioning axes
Reduce the number of positioning locations
Standardize positioning/fastening directions (for example, feeding from above)
Design special positioning locations to enable easier assembly
(for example, door hinges of different lengths)
ProKon Principles on Changing the Design
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Standardization of components
Reduce the number of components that require
different assembly methods
Standardization of fastening elements and torques
Reduce the number of tool changes, tool costs
ProKon Principles on Changing the Design
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Integration of components/functional integration
Reduce the number of components to be assembled
Integrate, for example, a fastening element in the component
ProKon Basic Value
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Basic Value describes the ideal assembly of a component or sub-assembly without considering any assembly interferences.
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)
Basic Value
ProKon Main Dimension > 300×300 mm
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Main Dimension > 300 x 300 mm refers to the dimensions of a com-ponent or sub-assembly that essentially determine its outer geometry.
Number of parts:
Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)
Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Main Dimension >300 × 300 mm
ProKon
Number of parts: Number
of tools
used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Process
visi-
bilityspace P1 P2 P3Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)
Dimension of Part > 800 mm
25 A/AA © MTM-Institut 28 Manual page
Dimension of Part > 800 mm describes a component or sub-assembly with at least one dimension > 800 mm.
If the main dimensions of a component are > 300 x 300 mm and one dimension is > 800 mm, then only the Assembly Interference Dimension of Part > 800 mm is evaluated.
Dimension of Part > 800 mm
Note
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Number of Positioning Locations
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two positioning locations several positioning locations one positioning location
Number of Positioning Locations refers to the number of locations in which a component or sub-assembly has to be positioned to reach its final position.
Number of Positioning Locations
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Restriction due to Visibility/Space
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Restriction refers to an assembly process in which obstructions may occur, due to poor visibility or insufficient space.
Restriction due to visibility/space
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Improper Fitting Possible
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Layout
Improper Fitting Possible refers to an assembly process in which it is possible to assemble a component or sub-assembly in more than one way. One or more of the possible fitting positions may be wrong (Poka Yoke).
Improper Fitting Possible
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Holding in Place Required
31 A/AA © MTM-Institut 32 Manual page
Holding in Place Required refers to an assembly process in which a component or sub-assembly is not in a stable (final) position after initial positioning.
Holding in Place Required
ProKon Example on Holding in Place Required
31 A/AA © MTM-Institut 33 Manual page
1. Place base plate in stable position
2. Lay washer on base plate and hold it in place
3. Place lock washer on washer and hold it in place
4. Position bolt through lock washer and washer and hold it in place
5. Engage thread
6. Turn on and tighten bolt
Base plate
Bolt
Lock washer
Washer
Example: Assemble bolt with lock washer and washer
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Readjustment while Positioning
32 A/AA © MTM-Institut 34 Manual page
On the X-axis the position is defined by stops. On the Y-axis there is no stop, so readjustment is necessary.
Readjustment while Positioning refers to additional corrective motions that are required to place the component in its final position, following its initial positioning.
Readjustment while Positioning
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Without Positioning Aids
32 A/AA © MTM-Institut 35 Manual page
Without Positioning Aids refers to an assembly process in which neither the component or sub-assembly, nor the positioning location is equipped with positioning aids, such as stops, guides, etc.
without positioning aid
with positioning aid
Without Positioning Aids
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Change in Positioning/Fastening Dir.
33 A/AA © MTM-Institut 36 Manual page
Change in Positioning Direction becomes necessary, within a positioning process, if a component or sub-assembly has to be positioned in more than one direction along a defined positioning axis.
Change in Fastening Direction exists if a component or sub-assembly has to be fastened in more than one fastening axis/direction along at the destination.
Change in Positioning/ Fastening Direction
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Adjustment/Check
35 A/AA © MTM-Institut 37 Manual page
Adjustment/Check refers to design-caused processes that must be performed prior to completing subsequent activities.
Adjustment/ Check
ProKon
Number of parts: Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Processes
36 A/AA © MTM-Institut 38 Manual page
All activities that are not performed for the purpose of positioning components are called Processes.
Processes
ProKon
Number of parts:
Assembly Steps ≤ 8 kg > 8 kg 2 3 >3
Adjust-
ment/
Check
Processes
visi-
bilityspace P1 P2 P3
Readjust-
ment
while
Position-
ing
Without
Position-
ing Aids
Change in
Positioning/
Fastening
Direction per
axis (x, y, z)
Number
of Tools
Used
Basic Value Assembly Interferences
Weight, incl.
1st positioning
location
Main
Dimension
>300×300
mm
Dimen-
sion
of Part
> 800
mm
Number of
Positioning
Locations
Restriction
due to Improper
Fitting
Possible
Holding
in Place
Required
Number of Tools Used
37 A/AA © MTM-Institut 39 Manual page
Number of Tools Used indicates the number of tools required to perform an assembly. (For example, changing a socket would require an entry in this column.)
Number of Tools Used
ProKon Time-Influencing Factors
39 A/AA © MTM-Institut 40 Manual page
ProKon
Units
The primary sector describes those influencing factors in the ProKon Analysis Sheet (ProKon Units) that affect the positioning location itself and thus, directly impact the assembly time.
The secondary sector describes influencing factors that affect such things as parts supply and layout design at and around the work station and thus, indirectly impact the assembly time. Overall Work System
ProKon Possibilities for Time Data Determination
39/40 A/AA © MTM-Institut 41 Manual page
Creation of an MTM Planning Analysis based on the parameters defined for the future work system to be established for the new product
Reference to existing MTM data previously developed for a sufficiently comparable product, while adjusting details, where required
Comparison with a reference product, while estimating significant deviations
The time value established is utilized in the calculation of the factor, as described below:
∑ ProKon Units × Factor = Assembly Time (minutes)
Time value from analysis (real assembly time) in min
∑ ProKon Units = Factor
ProKon Example: Collar Band
42 A/AA © MTM-Institut 42 Manual page
Assembly Steps • Place anchor into pre-drilled bore hole
• Drive in anchor
• Place collar band on anchor
• Place screw and turn it in
Present Design
ProKon Example: Collar Band
42 A/AA © MTM-Institut 43 Manual page
Assembly Steps • Place collar band
• Place nail anchor and drive it in with hammer and hand tool
Proposed Design – Variant A
ProKon Example: Collar Band
42/44 A/AA © MTM-Institut 44 Manual page
Description Number of
components ProKon Units %
Present Design 3 385 100
Proposed Design - Variant A 2 255 66
Proposed Design - Variant B 1 135 35
Assembly Steps • Place collar band with integrated anchor into pre-drilled bore hole and press it in
Proposed Design – Variant B
ProKon Example: Car Headlight
49 A/AA © MTM-Institut 45 Manual page
Assembly Steps •Place headlight housing
•Place self-tapping screw to z-axis and turn on
•Place self-tapping screw to y-axis and turn on
•Place washer and nut to ×-axis and turn on
Tapping screw to z-axis
Tapping screw to y-axis Washer and
nut to x-axis
Present Design
ProKon Example: Car Headlight
49/51 A/AA © MTM-Institut 46 Manual page
Assembly Steps Place headlight housing on locking pins
Place self-tapping screw and turn on
Description Number of
components ProKon Units %
Present design 5 835 100
Proposed design 2 345 41
Circular rubber sealing
Locking pins to x-axis
Tapping screw to x-axis
Proposed Design
ProKon Project AX: Sun Visor Retainer
55 A/AA © MTM-Institut 47 Manual page
Inside bracket Cover cap
2 self-tapping screws
Assembly Steps
• Get bracket
• Position to 2 bore holes in front center of inner roof lining
• Fasten bracket with 2 self-tapping screws
• Get cover cap
• Engage cover cap in bracket
Present Design
ProKon Project AX: Sun Visor
55 A/AA © MTM-Institut 48 Manual page
1st Engage (bracket)
2nd Engage (cover cap)
Assembly steps
• Get bracket
• Position to front center of roof lining
• Engage bracket (1st engage)
• Get cover cap (fasten to bracket by film hinge)
• Engage (2nd engage)
Proposed Design
ProKon Project AX: Sun Visor – Result
55 A/AA © MTM-Institut 49 Manual page
State of Design Components Production Time
Present Design
1 bracket
2 tapping screws
1 cover cap
0.50 min per retainer
Proposed Design
1 bracket with integrated
fastening elements
1 cover cap
0.25 min per retainer
Delta per retainer 0.25 min per retainer
2 retainers are assembled to every car. This results in a reduction in production time of 0.50 min per car. In addition, 4 tapping screws, with a material value of € 0.08, can be omitted.
ProKon Success Factors
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Customer Orientation • Company focuses on its customers‘ wishes.
Added Value • All non value-adding activities are to be avoided.
Standardization • Mastering the diversity of types and models through standardization.
Many variants with few variables (using identical components and sub-assemblies)
• Formalization of processes with clearly defined interfaces (no double work on the system boundaries)
Thinking and Planning Ahead • Acting instead of reacting, i.e., it’s better to avoid problems than to
eliminate them.
ProKon Success Factors
59 A/AA © MTM-Institut 51 Manual page
Small, Controllable Steps • Feedback from one step controls the following step. Consequently, if
errors occur, they will not be as severe and can easily be corrected.
Elimination of Errors at the Root of the Problem • To prevent the repetition of an error, its cause, not its effect, has to
be eliminated.
Personal Responsibility • The responsibility for any job lies with the person performing this job,
i.e., staff members become co-entrepreneurs.
Team • All for one and one for all, i.e., it’s the team’s results that counts.
Continuous Improvement • Continuous improvement of all performances at any time, i.e., the
journey is the reward.