Final Presentation 223 (test)

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CPR Consulting Analysis of Press and CNC Operations at C&D Zodiac:

CPR Consulting Analysis of Press and CNC Operations at C&D Zodiac By Zhiyu Ran, Logan Pace, & Corey Cassell

Items to Be Covered:

Items to Be Covered Project Overview Press Operation Press Recommendations CNC Operation CNC Recommendations Recommendations for future students

Project Overview:

Project Overview Apply various process improvement tools to a real work place Use data and evidence to solve problems and/or come up with recommendations for improvement

C&D Zodiac:

C&D Zodiac

Aircraft Interior, seat shells:

Aircraft Interior, seat shells

Press Operation:

Press Operation

Press Floor Plan and Spaghetti Diagram:

Press Floor Plan and Spaghetti Diagram

Collected Press Time Study Data:

Collected Press Time Study Data Medium Panel Assembly Average Lay Fiberglass 2.84 Lay Crushcore 4.19 Lay Fiberglass 5.05 Tape Edges 1.42 Total Observed Time 13.51 Clock Time 16.25 Large Panel Assembly Average Lay Fiberglass 2.96 Lay Crushcore 1.76 Lay Fiberglass 3.53 Tape Edges 4.93 Total Observed Time 13.18 Clock Time 16.21 Flyback timing was used to measure each element of the panel assembly process Very similar total set up times More active tables Have workers produce at a higher rate while cook cycle is in progress

Operation Process Chart for Press:

Operation Process Chart for Press

Press Machine Work Sampling:

Press Machine Work Sampling Machine Work Sampling Time Press 1 Press 2 Press 3 Press 4 Press 5 Day 1 1 panel just removed closed has a panel heating up no tool, open 2 has a panel closed has a panel heating up no tool, open 3 has a panel closed has a panel heating up no tool, open 4 has a panel closed panel just loaded heating up no tool, open 5 panel just loaded closed has a panel heating up no tool, open 6 has a panel closed has a panel heating up no tool, open 7 has a panel closed panel just loaded heating up no tool, open 8 has a panel closed has a panel heating up no tool, open 9 has a panel closed panel just loaded heating up no tool, open Day 2 10 closed open with panel closed open with panel open 11 closed open closed closed closed with panel 12 closed has a panel closed open with panel closed with panel 13 closed has a panel closed closed with panel closed with panel 14 closed has a panel closed closed with panel closed with panel 15 closed open with panel closed open with panel closed with panel 16 closed closed with panel closed closed with panel closed with panel Press Machine Work Sampling # observed % time spent hours Production 39 0.49 1.06 Inactive 32 0.40 0.87 Heating 9 0.11 0.24

Press Worker Work Sampling :

Press Worker Work Sampling Press Press Operating press Measuring panel Throwing trash Working on panel Working on panel Working on panel Working on panel Examining panel MIA Working on panel MIA Working on panel MIA Working on panel MIA Working on panel LUNCH Working on panel LUNCH Working on panel LUNCH Put weights on panel LUNCH MIA Spraying press Working on panel Operating press Working on panel About to make panel Working on panel MIA Working on panel Working on panel Working on panel Working on panel Working on panel Working on panel Working on panel Working on panel Working on panel Press (40 total observations) # observed % time hours Inspection 2 0.05 0.25 Wasted Time 6 0.15 0.75 Production 26 0.65 3.25 Non value 6 0.15 0.75 added necessary

Press 5s Analysis:

Press 5s Analysis Current setup Where improvements can be made Shadow boxes instead of tool boxes

Adhesive Suggestions:

Adhesive Suggestions Downsides of the current method Possible Alternatives Dot Shot Pro Hot Glue Gun

CNC Operation:

CNC Operation

CNC Floor Plan and Spaghetti Diagram:

CNC Floor Plan and Spaghetti Diagram

TRF Recommendations:

TRF Recommendations Alternative TRF types Universal tooling Hollow Mahogany Wood Molds

TRF Upgrade ROI Analysis:

TRF Upgrade ROI Analysis ROI Assumptions Price (Per C&D Zodiac Quote) - $200,000 Maintenance - $15,000 per year Employee training - $10,000 TRF Cost – 10 Tools at $12,500 per tool. 2 Product Lines per year

Analysis of Company Self Improvement methods:

Analysis of Company Self Improvement methods Zodiac Lean Team Data Collection Discrepancies Brightly Colored jackets may be responsible for intimidating workers

Future Recommendations:

Future Recommendations Pick some place close Have a plan before showing up

Future Recommendations:

Future Recommendations Make it interesting for yourself

Future Recommendations:

Future Recommendations Think about what YOU are getting out of it Do what’s important

The End:

The End Thank you

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