HEV INTERN PROJECT SUMMARYPresentation to: Management

Presented by: Rogelio Fonseca

Date: August 16, 2016

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

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Rogelio Fonseca

• University of Houston

• Industrial Engineering/ Computer Science

• Graduating May 2017

Introduction

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Problem Statement

A lot of very useful data can be collected on the manufacturing floor. • Measurements• Cycle times• Defect problemsHow 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?

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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

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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 checkLets other GLs know that a check has been completed by someone else

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Daily CS Database - Usage

Out-of-tolerance values are highlighted in red to alert at the point of measurement to improve recognition time

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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% improvementOld recognition time (worst case): 2 months (20160 min) 99.95%

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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.

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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

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Daily CS Database - Summary

99% reduction in bad value recognition time96% reduction in SV and QC check sheet burden40 pounds of paperwork saved per yearTo-Do list for check sheets makes objectives clearEach check sheet now has its own notesQuick retrieval of past dataDatabase data can be analyzed in Excel or MinitabGreatly increased compliance with our proceduresSupervisors 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

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Project 2: Live Production Graphs

Enable quick data analysis, for daily review or improvement projects

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Example data project: GS Bottom Height Rework

History of Rework (from 81332 GS produced)Tester limit set at 32mm, spec limit is 33mm8466 (10.4%) were over 32 mm (47 hours rework)774 (0.95%) were over 32.5 mm (4.3 hours rework)

TrialBased on data, checking 32.5mm (yellow area) is acceptable

BenefitUp to 42.7 hours/year saved (91% reduction)No expense or training required

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30 Day Trial

Proposed Benefit91% reduction in rework

Last 30 Days - 7974 GS produced875 (11%) were over 32 mm 77 (0.96%) were over 32.5 mm

Actual 30 day Benefit4.5 hours saved (91.2% reduction) = 150 extra GS producedEquals 1423 extra GS at last year’s rate

Setting: 32 mm Setting: 32.5 mm0

50100150200250300350

Rework Minutes

Rework Minutes

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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

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Project 3: Line Out Database

?

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Line Out Database - Interface and functionality

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Line Out Database – Sorting and Usage

Line Out and scrap being recorded in databaseAllows for live graph display of line outs and scrapAllows for automation of OEE calculation and more accurate first-time-thru

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What I LearnedTechnical• 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.

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Thank You!

Questions?