References / Acknowledgements Application of Lean Six Sigma ...
Undergraduate Category: Engineering and Technology Degree Level: Industrial Engineering, B.S. Abstract ID# 1461
Application of Lean Six Sigma Methodology for Improving Productivity of Armboard Manufacturing Kevin Carr, Luke Fisher, Sean Lerkvikarn, Leo Poggie Project Conducted at: Allen Medical Systems, Acton, MA 01720 Abstract
Results
v Medical device manufacturing plants struggling to balance producDon efficiency with introducing new products v Using Six Sigma DMAIC cycle along with Lean Manufacturing to reduce waste, enhance producDvity, and improve quality v Case Study: Improving armboard producDon process at Allen Medical Systems through Kaizen events, Dme studies, flow charts, and other Lean Six Sigma tools v ReducDon of non-‐value added acDviDes along with restructuring of process reduced cycle Dme by ~90 s/unit and increased producDon output from 5.3 units/hr to over 6 units/hr v Successful implementaDon of improved process led to significant cost savings for Allen Medical
v Established single-‐piece flow for applicaDon of adhesives and packaging of individual armboards à 45 s/unit savings v Eliminated bag removal step à 10 s/unit savings v Designed a fixture to secure armboard during nut-‐washer-‐screw assembly à 6 s/unit savings v Removed dot cover à 5 s/unit savings v Reconfigured parts presentaDon/layout à savings unknown
Before
After
Background v 60 operators in facility (12 salaried) v 42 different armboard models sold v Sales volume ≈ 475 units/month v Highest volume product ≈ 76 units/month v DistribuDon of Armboard Sales: o 25.4% INT o 55.2% OEM o 19.4% US
Conclusion v Implemented operator self-‐monitoring system in which the operator tracks the number of orders processed to control mfg. pace v Provided background data for future Kaizen event projects v Updated work instrucDons to include standards for operator manual movements v Retrained operators with regards to new fixtures and procedures v AddiDonal acDon items planned out requiring further research: o Using different type of LocDte to reduce cure Dme and establish single-‐piece flow throughout process (required safety tesDng) o CreaDng fixture for crimping of rivets in armboards
References / Acknowledgements Armboard Kaizen Event Screw Blade
Spring Trigger Teeth
Pad Paperwork Prep
Wear Strip Latch Cover
Snaplock Teeth
Board Lock Assy.
Cleaning
Adhesives
Pad Paperwork Bag Cart Close WO
Snaplock Assy.
700
600
19 35.4 49.9
500 87.3
19 24.5 41.2
TIME (SECONDS)
57.7 400 109.6 109.6 300
19 46.7 33.5
200
55.2
19 46.7 33.5 45.2
79 100
79
88.9
73.3
Before Kaizen
Ajer Kaizen
0
v Special RecogniDon: v Kim Rhy v Steve Tecce v Scog Wishart v Barry Hixon v Sean Morrissey
Application of Lean Six Sigma Methodology for Improving Productivity of Armboard Manufacturing Kevin Carr, Luke Fisher, Sean Lerkvikarn, Leo Poggie Project Conducted at: Allen Medical Systems, Acton, MA 01720 Abstract
Results
v Medical device manufacturing plants struggling to balance producDon efficiency with introducing new products v Using Six Sigma DMAIC cycle along with Lean Manufacturing to reduce waste, enhance producDvity, and improve quality v Case Study: Improving armboard producDon process at Allen Medical Systems through Kaizen events, Dme studies, flow charts, and other Lean Six Sigma tools v ReducDon of non-‐value added acDviDes along with restructuring of process reduced cycle Dme by ~90 s/unit and increased producDon output from 5.3 units/hr to over 6 units/hr v Successful implementaDon of improved process led to significant cost savings for Allen Medical
v Established single-‐piece flow for applicaDon of adhesives and packaging of individual armboards à 45 s/unit savings v Eliminated bag removal step à 10 s/unit savings v Designed a fixture to secure armboard during nut-‐washer-‐screw assembly à 6 s/unit savings v Removed dot cover à 5 s/unit savings v Reconfigured parts presentaDon/layout à savings unknown
Before
After
Background v 60 operators in facility (12 salaried) v 42 different armboard models sold v Sales volume ≈ 475 units/month v Highest volume product ≈ 76 units/month v DistribuDon of Armboard Sales: o 25.4% INT o 55.2% OEM o 19.4% US
Conclusion v Implemented operator self-‐monitoring system in which the operator tracks the number of orders processed to control mfg. pace v Provided background data for future Kaizen event projects v Updated work instrucDons to include standards for operator manual movements v Retrained operators with regards to new fixtures and procedures v AddiDonal acDon items planned out requiring further research: o Using different type of LocDte to reduce cure Dme and establish single-‐piece flow throughout process (required safety tesDng) o CreaDng fixture for crimping of rivets in armboards
References / Acknowledgements Armboard Kaizen Event Screw Blade
Spring Trigger Teeth
Pad Paperwork Prep
Wear Strip Latch Cover
Snaplock Teeth
Board Lock Assy.
Cleaning
Adhesives
Pad Paperwork Bag Cart Close WO
Snaplock Assy.
700
600
19 35.4 49.9
500 87.3
19 24.5 41.2
TIME (SECONDS)
57.7 400 109.6 109.6 300
19 46.7 33.5
200
55.2
19 46.7 33.5 45.2
79 100
79
88.9
73.3
Before Kaizen
Ajer Kaizen
0
v Special RecogniDon: v Kim Rhy v Steve Tecce v Scog Wishart v Barry Hixon v Sean Morrissey
