1. HEV INTERN PROJECT SUMMARY
Presentation to: Management
Presented by: Rogelio Fonseca
Date: August 16, 2016

2. 11
Overview
• Introduction
• Problem statement
• Project 1
• Project 2
• Project 3
• What I learned
• Questions

3. 22
Rogelio Fonseca
• University of Houston
• Industrial Engineering/
Computer Science
• Graduating May 2017
Introduction

4. 33
Problem Statement
A lot of very useful data can be collected on the
manufacturing floor.
• Measurements
• Cycle times
• Defect problems
How can this data be collected quickly and accurately?
How can it be quickly used to create improvements to
reduce rework, scrap and another elements that might
increase costs?

5. 4
Project 1: Daily Check Sheet Database
Old System (paper check sheets)
• Out-of-tolerance values are usually caught by SV or QC during review
• SV and QC may not catch the out of spec values among the dozens of check
sheets reviewed daily, and could be caught days or weeks after
measurement

6. 5
Daily CS Database - Menu
Check sheet menu shows GLs what check sheets remain, and what periodic
check sheets are due soon or overdue.
Decreases chances of a forgotten check
Lets other GLs know that a check has been completed by someone else

7. 6
Daily CS Database - Usage
Out-of-tolerance values are highlighted in red to alert at the point of
measurement to improve recognition time

8. 7
Daily CS Database - Signatures
Entire check sheet is flagged to eliminate accidental misses by GL, QC, or SV.
Will only sign bad value check sheets reducing check sheet burden by 96%
(from 46 daily to only and average of 2 daily).
New recognition time: instant (10 min max to finish and report it)
Old recognition time (best case): 1 shift (630 min) 98.4% improvement
Old recognition time (worst case): 2 months (20160 min) 99.95%

9. 8
Daily CS Database - Review
Group leaders can add a note for each date, instead of one field for an entire
month.
Easier to trace problem descriptions.

10. 9
Daily CS Database - Review
Check sheet data in a database allows easy retrieval, review, and analysis
instead of just record control
Recently used to check a week of varnish weights at beginning of shift

11. 10
Daily CS Database - Summary
99% reduction in bad value recognition time
96% reduction in SV and QC check sheet burden
40 pounds of paperwork saved per year
To-Do list for check sheets makes objectives clear
Each check sheet now has its own notes
Quick retrieval of past data
Database data can be analyzed in Excel or Minitab
Greatly increased compliance with our procedures
Supervisors and QC/Maintenance can log notes upon signing
3.5 lb of paper replaced by only 200 kb of data
One month worth of check sheets

12. 11
Project 2: Live Production Graphs
Enable quick data analysis, for daily review or improvement projects

13. 12
Example data project: GS Bottom Height Rework
History of Rework (from 81332 GS produced)
Tester limit set at 32mm, spec limit is 33mm
8466 (10.4%) were over 32 mm (47 hours rework)
774 (0.95%) were over 32.5 mm (4.3 hours rework)
Trial
Based on data, checking 32.5mm (yellow area) is acceptable
Benefit
Up to 42.7 hours/year saved (91% reduction)
No expense or training required

14. 13
30 Day Trial
Proposed Benefit
91% reduction in rework
Last 30 Days - 7974 GS produced
875 (11%) were over 32 mm
77 (0.96%) were over 32.5 mm
Actual 30 day Benefit
4.5 hours saved (91.2% reduction) = 150 extra GS produced
Equals 1423 extra GS at last year’s rate
0
50
100
150
200
250
300
350
Setting: 32 mm Setting: 32.5 mm
Rework Minutes
Rework Minutes

15. 14
Bottom Height Gauge Failures
Concern:
Relaxing test standard may cause more line outs after varnish
Last 4 months of line out data:
7.25 gauge line outs/month average
During 30 day trial:
4 line outs
No significant increase in gauge line outs during trial

16. 15
Project 3: Line Out Database
?

17. 16
Line Out Database - Interface and functionality

18. 17
Line Out Database – Sorting and Usage
Line Out and scrap being recorded in database
Allows for live graph display of line outs and scrap
Allows for automation of OEE calculation and more accurate first-time-thru

19. 18
What I Learned
Technical
• Use of SQL server.
• Got a chance to observe the processes and tests required
to build a stator or rotor.
• How to use some tools that I had never worked with before
while setting up the touchscreens and other line
improvements.
• The importance of designing things that are user-friendly
and intuitive.
• Thorough debugging of code is important to prevent
interruptions to a project.
Soft skills
• How to use all the tools available in order to solve a difficult
problem and not to be afraid to ask for help. (Online forums
are great!).
• Not giving up after something has failed countless times.
• Be attentive to the opinions of others as they will
sometimes have much better ideas than your own.

20. 19
Thank You!
Questions?