John Deere Tractors 5415 Diagnostic Repair Service Manual.pdf
Optimization and Standardization of Air Intake and Valve Cover Assembly Lines Presentation
1. TELAMON AIR INTAKE & VALVE COVER
SUBASSEMBLY LINE IMPROVEMENT
PROPOSAL
Team 28: Avishek Ray, David Chen, Hao Ma,
Joseph Zakhary, Mani Kumar
Client: Telamon Industrial Solutions
Location: Carmel, IN
Faculty Mentor: Prof. Shimon Y. Nof
Course Mentor: Maithilee Motlag
Client Contact: Jason Hale
2. AGENDA
• Problem statement
• Methodology
• Analysis and Findings
• System Model
• Results
• Discussion
• Reflection
3. PROBLEM STATEMENT
The Air Intake & Valve Cover subassembly lines need to reduce
overtime and improve standardization to face the challenge of large
customer order quantity. The formal problem statement is:
“The Optimization and Standardization of the Air Intake and Valve
Cover Subassembly lines at Telamon Industrial Solutions to increase
work efficiency and improve production rates by about 10-15%.”
5. Observation
• Evident bottlenecks in
the assembly process
• Opportunities to
improve efficiency on
the production lines
Operator
Interviews
• Production specific
questions
• Feedback on their
pain points during
assembly
Ergonomic
Analysis
• MTM-1
Analysis/Time
studies
• Dassault CATIA
reach envelope
analysis
7. MTM-1 & ERGONOMIC ANALYSIS FINDINGS:
VALVE COVER CELL
• Collecting and pasting
barcode should be done
during gasket-press
automation
• Gluing should start from
right edge of valve cover
castings
8. MTM-1 & ERGONOMIC ANALYSIS FINDINGS:
AIR INTAKE CELL
• Pre-tightening of bolts on air
connector with screwdriver is
unnecessary
• Side desk of workstation is out
of reach distance
• Unnecessary walking during
assembly procedure
• Gaskets are difficult to reload
11. Exit Pallet Carousel
Optimized tray for the gaskets and screws
Reduces unergonomic reach and assembly time
CATIA model of an optimized workstation
based on reach analysis
Walmart inspired
packaging technique
to improve efficiency
in filling up pallets
post assembly
13. Production Coordination
Software/ remote-controlled Bingo
Board
Post Assembly Machine Vision QC
VS2 Samsara Guide
Optimizing production using Andon
Studios software
Line assist
signals for better
floor
communication
Seamless QC
performed by
VS2 Samsara
mounted
overhead the
packaging
pallet
VS2
Samsara
15. Cell 2700
With post-assembly
Machine vision QC
Cell 2000
With post-assembly
Machine vision QC
Cell 2600
With post-assembly
Machine vision QC
Supplies
Parts to
Rejected
Parts
Rejected
Parts
Air intake
Valve Cover
Rejected
Parts
Defective
Parts
Has price
authority over
Quality
Defective
Parts
Telamon Warehouse
@ Carmel, IN
Parts Suppliers
Cummins
Cell 2000
Stop after filling
every pallet level
Supplies
Parts to
Air
Intake
Valve
Cover
Rejected
Parts
Rejected
Parts
Must
inspect
before
proceeding
Must inspect
before proceeding
Must inspect
before
proceeding
Defective
Parts
Cummins
Has price
authority
over
Quality
Defective
Parts
Telamon Warehouse
@ Carmel, IN
QC per pallet level
by traveling
Inspector (Kim)
Parts Suppliers
Cell 2700
Stop after filling
every pallet level
Cell 2600
Stop after filling
every pallet level
QC per pallet level
by traveling
Inspector (David)
18. 24%
48%
4%
24%
PERCENTAGE TIME SAVED BY EACH
SOLUTION PER WORKSTATION
435
365
0
100
200
300
400
500
Current Production Time Improved Production Time
Minutes
Overall Time Savings in a
workday
9%
31%
16%
44%
PERCENTAGE COST SAVED BY EACH
SOLUTION IN A YEAR
16%
reduction in
time
19. DISCUSSION
• Concerns about installing the pallet carousel
• Safety
• Opposition on necessity grounds
• Concerns about installing the production floor info system
• Additional server investment
• Fragile monitoring devices (tablets and iPads) on the work floor
• Additional training required to use the system
• Concerns about installing the machine vision technology
• Proper placement and detection of required QC instructions
• Potential adjustments in barcode placements to be detected by the
technology
21. What we enjoyed
Acknowledgments
• Being able to work with a real client
problem
• The freedom to brainstorm solutions
based on the learnings from our
previous courses
• The support of our client, our
professors and our faculty mentor
throughout the semester
We would like to extend our sincere gratitude and appreciation towards Telamon for giving us the opportunity to work
on such an intriguing project! It was a pleasure working with Jason Hale through this semester and we would like to
thank him for his transparency and prompt responses to all our questions! Also a huge thank you to everyone at
Telamon who has made our senior design experience so rewarding !
Key Learnings and Takeaways
• Difference between class and industrial
expectations
• Scope creep and understanding the key
pain points being asked to be solved in
the project
• Working cohesively as a team and
settling disputes amicably
• Responsibilities of an Industrial engineer
in the work force
Thank you Mani! To tackle our case our approach was divided into ergonomic improvements and industrial 4.0 improvemnst
Thank you Mani! To tackle our case our approach was divided into ergonomic improvements and industrial 4.0 improvemnst
As we observed the lines and production workstations during our visits at Telamon, we noticed an opportunity to improve the gasket holders in the air intake workstations. Secondly a rotating carousel would increase production and packaging efficiency as well!
Lastly we also conducted a CATIA reach analysis to understand if everything in the workstation is within industrial reach boundaries
We also considered Industrial 4.0 developments for our client and looked at a production coordination system as well as a post assembly machine vision QC
After vetting multiple companies such as Cognex omron and samasara, we narrowed down on the VS2 samsara model as it seemed to satisfy the overall QC needs of our client!
We also contacted the company to get a quote on the solution and built a relationship with them which Telamon could pick up if they do consider implementing the solution!
