Design Optimization for Dadant Product Work CellsBridgeway | Group #2

Students: Arielle Anderson-VenerableJordan PalmerKelsey Schreiber

Advisor: Prof. Sewoong Oh

Contact: Tammy DiefendorfScott TeelBrittany Aten

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OverviewBridgeway Introduction

Dadant & Sons

Assembly Tasks

Problem Statement

Objectives

Air Flow and Drying Options

Systematic Layout Planning

Line Balancing Analysis

Economic Analysis

Conclusions and Recommendations

Q & A

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“Creating Solutions for Everyone.”

Affirmative Employment ServicePhysical and/or mental disabilities

Consumer vs. Productionist

Contract Work Dadant & Sons -- Beekeeping Supplies

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Production Overview

Final Assembly and Packaging

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Frame Production

Hive Body Production

Shipping Box Construction

Frame Production (1 of 2)

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Frame Production (2 of 2)6

Hive Body Production (1 of 3)

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Hive Body Production (2 of 3)

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Hive Body Production (3 of 3)

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Final Assembly and Packaging

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Problem StatementImprove efficiency of facility layout

Reduce non-value added work & work in process

Decrease drying time for painted/primed hive bodies

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Objectives

Conduct time studies

Use Systematic Layout Planning (SLP)

Line Balancing Analysis

Establish and improve paint/primer drying time

Conduct economic analysis

Recommend improvements

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Paint Drying - Current State13

Primer Paint

Bridgeway Estimate 175 min - Overnight* 55 min - Overnight*

Label Estimate 60 min 60 min

*Current drying time highly variable due to environmental conditions.

Paint Drying - Environmental Improvements Move drying into paint room

Temperature Control

Dehumidifier

Air Ventilation

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[Ivation 2016, Vornado 2016]

Paint Drying - Systematic Improvements

● Digital/Kitchen Timers● Dry Erase Time Notation● Time Stamp Labeling

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[Amazer 2016, Cosmos 2016, Demarkt 2016]

SLP- Introduction

Quick material flow

Less WIP

Reduced handling

Subjective -> objectiveFlowPlanner

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[Muther 1973]

SLP- Flow Planner Initial Analysis17

● Product/Part Routes Mapped in AutoCad● Routes along Aisles● Wage and Walking Speed along paths● Aggregate per Monthly production

SLP - AEIOUX Analysis18

SLP - Design and Analysis Phase Used AEIOUX to guide design of new layouts

Maximize A, E, and I relationships

Analyze layouts in FlowPlanner

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SLP- Consulting with Bridgeway

● Selected layout 4● Not most Efficient but…

○ Sound Accommodations

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SLP - Layout Implementation

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Balance workload among workstations

Decrease Idle Time

Decrease work pile-ups

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Line Balancing- Introduction

Line Balancing- Unique Challenges

Typical Line Balancing

Involves assigning different tasks to same workstation or worker to balance workload

The Challenge

Consumers and Productionists are limited to very specific tasks based on abilities

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Line Balancing- Typical Method24

● A new unit enters next workstation every 15 minutes● Number of tasks/worker varies

Line Balancing- Alternative Approach

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● A new unit enters the next workstation every 5 minutes● Number of workers/task varies

Line Balancing- Precedence Diagram

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Must happen 10 times before next step:Total Time = 8.7 minutes

Line Balancing Summary

66% consumer employment increase

Minimum Cycle Time: 2.31 minutes

Constraint: Hive Body Construction

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Economic Analysis

Initial Cost: $1,629.00

Monthly Savings: $2,593.00

Monthly Recurring Costs: $24.00

Payback Period: 19 days

Monthly IRR: 155%

Yearly IRR: 1633%

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Economic Analysis- Supply Increase

97 bodies per day → 2143/month

Current average: 1664/month

Revenue increase: $2,933.00Total increase: $5,526.00

54% increase in average hive body revenue

29% increase in product throughput

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ConclusionsLoss of profit each month due to

layout

Hive body drying process is long

Bridgeway's supply from Dadant is inconsistent

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RecommendationsDesign

Drying Room

Dadant supplies

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Questions?

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Option #1

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Option #2

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Option #3

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Option #4

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Option #5

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Budget/Economic Analysis

Grant-based funding

Non-profit organization

Previous work with Dadant & SonsNon-standard payment setup

Short-term loss for long-term success

Supply restrictions

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Project Constraints

There are some constraints that the project team must account for, including: 1. Tasks, and how they are completed, must remain the same. Both consumers and

productionists are trained by an outside team, and restructuring training and specific tasks is not an option.

2. Productionists must complete all steps involving the movement of materials around the plant.

3. Frame stapling and box hammering must be kept away from the office as they interfere with communication.

4. Stapling equipment is not owned by Bridgeway, and thus is not eligible for possible design updates.

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Flow Planner - Aisle Routes (Large Hive Bodies)

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Flow Planner- Direct Paths (Large Hive Bodies)

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Flow Planner- Configuration,1 (Large Hive Bodies)

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Flow Planner- Configuration.2 (Large Hive Bodies)

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“Creating Solutions for Everyone.”

Est. 1993

Affirmative Employment ServicePhysical and/or mental disabilities

9000 people employed/served per year

Contract Work

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Project Location | Macomb, IL.

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Production Areas

Storage

Storage

StorageArea

Air Flow/Drying

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Space for Temporary Jobs

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Work in Process

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Drying Room Stairs

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Project Gantt Chart50

Work Flow51

SLP - Noise Constraints52

ISO Certification

Provide guidelines that can be used consistently to ensure that materials, products, processes and services are fit for their purpose

21000+ standards (for purchase)

Ensure products and services are safe, reliable, and good quality

Reduce costs by minimizing waste and errors, and increasing productivity

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[ISO.org]