designing products for cellular assembly

Designing Products for Cellular Assembly

Designing Products for Cellular Assembly

ADVENT DESIGN CORPORATIONADVENT DESIGN CORPORATIONBristol, PABristol, PA

Presentation GoalsPresentation Goals

Review use of Six Sigma design Review use of Six Sigma design methodology & DMADVmethodology & DMADV

Review how design impacts Review how design impacts assemblyassembly

Review coordination of design Review coordination of design development and cellular development and cellular assembly assembly

Transition to the Six Sigma Transition to the Six Sigma DMAIC cycleDMAIC cycle

Follow a new product through Follow a new product through the cellular design processthe cellular design process

Cellular ManufacturingCellular Manufacturing

Group products into familiesGroup products into familiesEstablish the required cycle timeEstablish the required cycle timeReview the production sequenceReview the production sequenceDesign the cell layoutDesign the cell layoutAdjust work to balance flowAdjust work to balance flow

Re-arranging production operations to improve flow and to reduce handling and cycle time

How is this done during the design process ?How is this done during the design process ?

The DMADV CycleThe DMADV CycleSix Sigma In ActionSix Sigma In Action

Define & Measure

Design• DFMEA

• Requirements

Analyze• Concepts

Verify•Breadboard• Prototype

System DesignSystem DesignTolerance DesignTolerance DesignParameter DesignParameter Design

Design for Six SigmaUse of DMADV

Design for Six SigmaUse of DMADV

Define:Define: Project Plan & ID RisksProject Plan & ID RisksMeasure:Measure: Voice of the Customer, CustomerVoice of the Customer, Customer

Requirements, Critical to QualityRequirements, Critical to QualityAnalyze:Analyze: Concepts, Key Functions, Design Concepts, Key Functions, Design

reviewsreviewsDesign:Design: High Level Elements, Design High Level Elements, Design

Requirements, FMEA, Design ReviewsRequirements, FMEA, Design ReviewsVerify:Verify: DrawingsDrawings, BOM, , BOM, PDCA, Bread board, PDCA, Bread board,

Prototype, Implementation PlanPrototype, Implementation Plan

Critical to Quality (CTQs) Convert Customer Needs into the Language of the

Design Team

Critical to Quality (Critical to Quality (CTQsCTQs) ) Convert Customer Needs into the Language of the Convert Customer Needs into the Language of the

Design TeamDesign Team

CTQsCTQs that affect cell designthat affect cell design……

Out of package start up reliability must be Out of package start up reliability must be 100% 100%

Process fluid batches must satisfy all Process fluid batches must satisfy all chemistry requirementschemistry requirements

No leaks in any fluid pathsNo leaks in any fluid paths

Analyze: Design & Process ConceptsAnalyze: Design & Process Concepts

Generate conceptsGenerate concepts

Combine conceptsCombine concepts

Select conceptsSelect concepts

Evaluate conceptsEvaluate concepts

REVISED BETA TECHNICAL CONCEPT

CONCEPT APPROACH The primary goals of the revised Beta design are to reduce unit cost and the size of the unit. This can be approached following three general paths:

1. Cost and size reduction of individual components without affecting the process:

• Tank(s) • Valves • Pumps • Sensors • Controls package

2. Cost and size reduction of individual components with some select process changes:

• Saline tank overflow fill of brine tank • Saline flow regulation by pump motor speed control • Catholyte re-circulation through a small, positive displacement pump

3. Significant process changes that target eliminating components and reducing complexity:

• Continuous process concepts that eliminate the saline tank. Regardless of the path selected, new components, whether resourced or re-sized or newly selected due to a process change, must be fully tested. The revised beta will require a new review by NSF and UL.

Process Concepts Lead to Machine Design

Process Concepts Lead to Machine Design

M

M

M

M

S

BRINE TANK(T1)

AQUALOX TANK(T3)

WASTE / DRAIN TANK(T4)

SV-1

P-3

P-4

P-5

FR-3

MV-1

MV-2MV-4

MV-3

pH CHAMBER AND PROBE

CATHOLYTE RECIRC

CHAMBER

STERILOX CELLS

HYDROGEN EXHAUST

CONTINUOUS PROCESS OUT

AQUALOX AUTO OUT

AQUALOX MANUAL OUT

WASTE / DRAIN OUT

EMERGENCY OVERFLOW OUT

POTABLE WATER IN

WASTE / DRAIN MANIFOLD

OVERFLOW TROUGH

BRINE PUMP(SPEED

CONTROLLED)PP-1

WASTE / DRAIN JETPUMP

P-6

AQUALOX PUMPSP-3, P-4,

P-5

SUMMARY OF DIFFERENCES COMPARED TO ALPHA PLUMBING SCHEMATIC (DWG 77818000):

1. THE SALINE TANK AND SALINE PUMP HAVE BEEN ELIMINATED. IN THEIR PLACES ARE A PRESSURE REGULATOR TO ENSURE CONSISTENT FLOW.

2. CLOSED LOOP CONTROL OF THE BRINE PUMP (USING FEEDBACK FROM AN IN-LINE CONDUCTIVITY METER) MAY NOT BE REQUIRED IF THE PROCESS IS STABLE WITH OPEN LOOP CONTROL.

3. CATHOLYTE RECIRULATION DRIVEN BY A SMALL MAG DRIVE PUMP.

IN-LINE CONDUCTIVITY

METER

PRECISIONPRESSURE

REGULATOR

?

SV-2

S

FR-1.44 GPM

FR-2.01 GPM

CATHOLYTE RECIRC. PUMP

DIAPHRAM TYPEP-2

SV-3

S

FR-4

Design Requirements & DFMEADesign Requirements & DFMEAThe Beginning of Cellular DevelopmentThe Beginning of Cellular Development

Product Component or Process Step

Failure Mode Failure Effects(Consequence of Failure) Causes Controls

7784-0004 Left Side Plate7784-0008 Right Side Plate

Sharp Edges Laceration hazard -to Advent Techs, Customer Service Techs, End users.

Laser cut not deburred as parts of manufacturing process

Deburring to be included in manufacturing process.Part will be inspected during first article inspection.

7784-0005 Base Right angle face not maintained at 90 deg

Assembly of side and top cover pieces difficult and causes top to buckle on assembly

Tolerance not specified and therefore not maintained in manufacture

Geometric tolerance specified on drawing. EVS will construct fixture to maintain perpendicularity during manufacture.Perpendicularity will be inspected during first article inspection.

7784-0010 Top Cover

Radius from pressing of PEM stud prevents stnd offs to seat consistently

Inability to use same parts (washers/spacers) on each stud in an assembly and between assemblies.User interface inoperable-keypad to mylar face distances vary and may be too far or too close to operate.

Cracked Welds Customer/End user disapproval -dissatisfaction.

Operator interface cut away bowed > 0.005"

Inability to use same parts (washers/spacers) on each stud in an assembly and between assemblies.User interface inoperable-keypad to mylar face distances vary and may be too far or too close to operate.

Manufacturing to support piece so that bow is minimized. Amount of Bow will be inspected upon first article inspection.

All Outside Covers Scratches/Sanding-swirl marks

Customer/End user disapproval -dissatisfaction.

Design Failure Modes & Effects AnalysisDesign Failure Modes & Effects Analysis• Failure modes• Consequences of failures• Causes• Controls

DESIGN REQUIREMENTS

General 1. Mechanical:

a) Outside dimensions b) Target weight (dry): c) Fasteners and hardware d) W herever practical, component mounting will be modular

Options will be investigated to simplify connections to pumps and valves in order to reduce components and fittings.

e) Pump type to be self-prim ing. f) All outlet ports from the unit shall be ½ FNPT.

2. Safety: a) Identified hazards will be labeled and/or guarded. b) Guards that lim it access to identified hazardous

components will require tools to be removed or will be interlocked.

c) Construction with respect to electrical safety: (1) Unit will be constructed to m inim ize risk of liquids

coming in contact with hazardous voltages (60 volts peak or 50 VDC).

(2) The electrical enclosure will be open ventilated. As a result, there are scenarios that could result in water entering the enclosure. The frame, panels, and enclosure openings will be designed to minimize this risk. Plumbing leaks and piping/fitting failures will be taken into account.

3. Ambient environmental operating requirements (temperature, humidity, etc.)

4. Codes / regulations: a) CUL b) NSF – unit will be designed following guidance of NSF

Criteria C-2 – 1983, Special Equipment and/or Devices. 5. Installation and service:

(1) Features to facilitate testing, packaging, transport, installation and service of the unit:

(2) Target service requirements (3) The Controller firmware shall be able to deduce

and provide indication of most likely fault using the Unit Controller to enter into a diagnostic and test mode using a portable computer and serial port into the Controller. It shall also be possible to view a detailed log of the Unit processing state values at the last good operating state and at the point of a Unit shutdown.

Design ReviewsDesign Reviews

Crossfunctional teamsCrossfunctional teams

Team discussionsTeam discussions

Customer Customer participationparticipation

Engineers & Engineers & assemblersassemblers

ADVENTDESIGN CORP.

CONTROLLED RECORD WHEN COMPLETED

ADVENT DESIGN CORP. CONFIDENTIAL- ALL RIGHTS RESERVED

QS-00-03-010 Rev. BPage 1 of 1 15-May-03FCG/drh

PROJECT MEETING FORM

Meeting Date:

Attendees:

Company Name: Project Name:

Major Items Discussed

Action Items Responsibility Projected Completion Date

Schedule Impact:

Budget Impact:

Use of 3 D ModelingEasy Visualization

Use of 3 D ModelingEasy Visualization

For AssemblyFor Assembly

For Maintenance For Maintenance AccessAccess

For InterferenceFor Interference

Design Development & Cellular Design Design Development & Cellular Design in Parallelin Parallel

An Iterative ProcessAn Iterative Process

Cellular Assembly Verification

Cellular Concepts

Define & Measure

Design• Requirements

• FMEA

Analyze• Concepts


• Drawings & BOM

Cellular Flow, Sequence, Layout

Cell Requirements

Cellular ConceptsBased on Design Concepts

Cellular ConceptsCellular ConceptsBased on Design ConceptsBased on Design Concepts

Selection of Main AssembliesSelection of Main Assemblies

Identification & Selection of Subassemblies Identification & Selection of Subassemblies Using 3D ModelUsing 3D Model

Modular Assembly ConceptsModular Assembly Concepts

Identification of complex assemblies for Identification of complex assemblies for fixturingfixturing

Basic Design Assembly ConceptBasic Design Assembly Concept

Tank & Frame Supports Assemblies

Electrical Assembly

Front PlateAssembly

Waste Tank& Jet Pump Assembly

Top Cover Assembly

Subassemblies Subassemblies

Assembly Sequencing

Main Assembly

Step1 Mount standoffs to plate and glue to inside mounting plate(77810004) to tank on side.2 Glue peristaltic pump plate to tank3 Glue PH probe plate to tank.4 Remove interior mounting plate5 Assemble motor to motor mounting plate( rotate head 90 deg)6 Assemble motor assy to mounting plate7 Assembly manual valves to tank8 Assemble motor mounting plate to tank with stainless hardware9 Assemble pump to frame10 Assemble casters to frame with stainless hardware (2 locking 2 fixed)11 Build waste manifold assembly (77810029)12 Assemble waste manifold assembly to tank13 Build Burkett 121/131 manifold.(77810032)14 Assemble 121/131 manifold to tank15 Build peristaltic pump assembly16 Assemble peristaltic pump to tank17 Build water in/Auqalox out valve assembly (77810031)18 Build water In valve assembly (77810033)19 Build Water in assembly (77810034)20 Install 1/2" tubing21 Make peristaltic pump tubing connections22 Place tank onto frame 23 Glue tank-to-frame blocks and align24 Install 1/2" tubing to catholyte chamber25 Glue cell mount blocks and catholyte chamber26 Build cell pack assembly27 Mount cell pack to tank28 Mount two pumps and make connections29 Install T3 manual drain and bracket30 Build lower valve assembly (77810030)31 Install lower valve assembly32 Install electrical wiring33 Install Transformer plate34 Install Electrical plate and 35 Install sensors and fix with tape36 Brine door assembly w/ hinges, lock and knob37 Install exhaust fans 1 in electrical box , 1 for exhaust38 Mount duct on skin for exit39 Install cabling for boards, sensors, valves40 Pressure test unit and check for leaks41 Fix leaks if found ( plan to build test fixtures prior to assembly to tank)42 Adjust sensors as necessary43 Fill tank with Brine44 Test unit to finalized test plan45 Make adjustments/recheck parts/ retest if problems occur46 Drain unit47 Flush unit with water48 Add external skins/ and top cover49 Add 4' hose and nozzle50 Polish unit, towel dry if necessary51 Place labels in accordance with UL standards/ including serial #52 Package unit, complete ISO paperwork/checkoff sheets53 Ship unit to customer

Subassemblies & Main Subassemblies & Main Assemblies Listed in Assemblies Listed in Proposed Assembly Proposed Assembly OrderOrder

Includes Final Test & Includes Final Test & PackagingPackaging

Preliminary Quality Preliminary Quality ChecksChecks

Preliminary Cycle timesPreliminary Cycle times

Sequence of Cellular Assembly StepsSequence of Cellular Assembly Steps

Cellular Assembly Flow ConceptsMain & Subassemblies

Cellular Assembly Flow ConceptsMain & Subassemblies

MechanicalMain Product Assembly

(See Assembly sequencing)

Tank Assembly

121&131 Manifold Assembly

(77810032)14 parts35 min

Frame Assembly

Assemble Pump to Frame 7 min

Valves to Tank6 min

Waste Manifold Assembly

(77810029)

Glue 1.Peristaltic plate 2. PH mount3. Catholite chamber4. Cell Mounting Block to Tank 32 min

Assembly Blocks to plates & Glue

to tank

Assemble casters to frame10 min

Machine Mainfold in house

Water in Assembly

(77810034)3 parts

Water In/Aqualox out Assembly (77810031)

7 parts

Glue Couplings to Manifold 24 hrs

3 min

Machine Manifold (77810007) &

Machine couplings

Water In Valve Assembly

(77810033)9 parts13 min

Subassemblies

Interior Plate Assembly

Assemble Pump to plate , rotate head of pump

add fitting15 min

NameTitle

Glue Mount top securing blocks

Electrical Main Product Assembly

Mount Tank to Frame

Add Electronics

Add Sensors

Add Cabling

Make connections

Leak testing /Product testing

(Test to Final Qualificaiton Test Plan)

Packaging/shipment

SubassembliesSubassemblies

Tank & FrameTank & FrameAssembliesAssemblies

Main Assembly & SubassembliesMain Assembly & Subassemblies

• Cell Pack SubassemblyCell Pack Subassembly•• Cell Pack Fits to Front Plate Assembly Cell Pack Fits to Front Plate Assembly •• Front Plate Fits to TankFront Plate Fits to Tank

Sub Assembly Flow

Main Assembly Flow

Preliminary Cell Work Process Flow & Sequence

Base,Fans, Line cordCell Power Supply

Sterilox Tank Assembly

Traveler checkbox # 1

Front Plate Assembly


Electrical Assembly


Mount componentsto power supply plate

Sub # 1A

Assemble boardsto plate

PeristalticPump Assy

Plumbing


Waste Tank/ Brine Tank/ Jet Pump Assembly


Test Unit# 7

Assemble Salt ChuteClose up & Pack

# 8

Shipping/ReceivingInspection/Parts Supply

# 9

Inlet/Outlet Plate Assembly & Test


Start traveler &

assign serial number

.

Build subassemblies

Assemble on Carts

Assembly Drawings & BOM Based on Cellular Flow

Assembly Drawings & BOM Based on Cellular Flow

•• Required partsRequired parts•• Assembly notesAssembly notes•• Quality requirements & checksQuality requirements & checks

Base,Fans, Line CordCell Power Supply

Sterilox Tank Assembly7756-1104 & 1128

Traveler initial box # 1

Front Plate Assembly7756-1110


Electrical Assembly7756-1119


Build Cell Power Supply

7756-1112

Sub Assembly Flow

Main Assembly Flow

Cellular Assembly Flow & Sequence Chart

Plumbing & Waste Tank/ Brine Tank

/ Jet Pump Assembly7756-1100


Burn-In & Test Unit

Add test data to traveler

Assemble Salt Chute & Top Cover

Close Up & UL Test7756-1111

Traveler initial box

ReceivingInspection/Parts Supply

Inlet/Outlet Valve Assembly & Test

7756-1125Traveler initial box # 2

Start traveler &


Build pH Chamber7756-1115

Brine Tank assembly

7756-1106

Jet Pump & Waste Tank

assembly7756-1108

Assemble Boardsto Electric Plate

PeristalticPump

Assembly7756-1117

Package UnitQuality Assurance Checklist Review

Sign traveler

Build Cell Pack

7756-1113

Build Outlet assembly

7756-1126

Build Inlet assembly

7756-1109

Build conductivity probe7756-1116

Build Catholyte Chamber7756-1114

Remote programmingport

7756-1118

Tubing7756-1129

U/I assembly7756-1124

Cover assembly7756-1102

Labeling7756-1102

Supervisor OK to ship CheckSign traveler

Sterilox tank & sensor

7756-1107


Guidelines for Lean Cell DesignGuidelines for Lean Cell DesignGuidelines for Lean Cell DesignEach operation is ergonomically designedEach operation is ergonomically designed

Machines are arranged in the sequence of Machines are arranged in the sequence of operations needed to process the partoperations needed to process the part

All operations needed to make the part in the All operations needed to make the part in the cell and have process time < CT or cell and have process time < CT or TaktTakt timetime

Work stations equipped with Work stations equipped with pokayokespokayokeswhich perform as self inspectionswhich perform as self inspections

Aisle width is 4 ft.Aisle width is 4 ft.

Preliminary Cell LayoutPreliminary Cell Layout

Follows Cell Flow and SequenceFollows Cell Flow and SequenceImplementation PlanningImplementation Planning

Questions to Ask About the Value Stream Represented by the Cell

Questions to Ask About the Value Questions to Ask About the Value Stream Represented by the CellStream Represented by the Cell

Is the operation valuable?Is the operation valuable?

Is the operation flexible?Is the operation flexible?

Is the operation cycle time within takt time?Is the operation cycle time within takt time?

Are the operations balanced?Are the operations balanced?

Verify Design & Cellular ConceptVerify Design & Cellular Concept

Bread BoardBread Board•• Verify design conceptsVerify design concepts•• Parameter Design of Parameter Design of

Experiments Experiments PrototypesPrototypes

Verify design & cellVerify design & cell

Verify BOM & Material Staging for the Cell

Verify BOM & Material Staging for the Cell

Lead timeLead time

Space AvailabilitySpace Availability

Reduce cell Reduce cell assembler material assembler material handlinghandling

Level of Material Level of Material Control (kanban)Control (kanban)

Verify Quality SystemVerify Quality System

Final TestFinal Test

Work Station ChecksWork Station Checks

Vendor Process Vendor Process CapabilitiesCapabilities

DocumentationDocumentation

Build Customer Confidence!Build Customer Confidence!

Establish Assembler Knowledge & Training Requirements based on Cellular Design

ID Subassembly/Ope ra tion

T ank & Ba se Assy1 Cell Subassembly 1 X T T2 Cell Power Supply 1 T X T3 Base and Tanks 1 X T T

Inle t/Outle t assembly4 Inlet/Outlet Mounting Plate 2 - X T5 Jet Pump Water in Assembly 2 - X T6 Process Water In Assembly 2 - X T7 Output Valve Assembly 2 X X T

8 Assemble/Test Inlet/Outlet Assembly 2 X X T

Front Pla te Assy9 Catholyte Chamber Assembly 3 X X X X T10 pH Probe Assembly 3 X X X X T11 Conductivity Probe Assembly 3 X X X X T12 Assemble/Test Front Plate 3 X X X X T

Electrica l Assy11 Remote Program Port Assembly 4 T T X X X12 Electrical Plate Assembly 4 T X X X X X13 Signal Transformer Assembly 4 T X X T14 Peristaltic Pump Assembly 4 T X X15 Sensor Calibration 4 T X X X16 Cuno Jack Wiring/Soldering T X X T

17 Electrical Component Wiring/Mounting

4 T X X

Plumbing/T ubing18 Side Tubing Connections 5 X T

18 Tubing Interconnection-Aqualox Tank

5 X T

18 Waste Chamber & Front Plate Tubing 5 X T

19 Assemble Tank & Pump to unit 5 X T20 Jet Pump Assembly 6 X X21 Waste Chamber Assembly 6 X X T22 Brine Tank Assembly 6 X X T23 T est 7 T T X X24 Salt Door 8 T X X25 Ope ra tor Inte rface /Covers 8 T26 Ground Plug Assembly 8 T X27 Fina l Unit Check 8 T T X X28 Packing 9 T T X T

T - Trainer for taskX - Trained to perform task

Base,Fans, Line CordCell Power Supply

Sterilox Tank Assembly7756-1104 & 1128


Front Plate Assembly7756-1110


Electrical Assembly7756-1119


Build Cell Power Supply

7756-1112

Sub Assembly Flow

Main Assembly Flow

Pre-Production Cellular Assembly Flow, Sequence & Quality Chart

Plumbing & Waste Tank/ Brine Tank

/ Jet Pump Assembly7756-1100


Burn-In & Test Unit

Add test data to traveler

Assemble Salt Chute & Top Cover

Close Up & UL Test7756-1111


ReceivingInspection/Parts Supply

Inlet/Outlet Valve Assembly & Test

7756-1125Traveler initial box # 2

Workstation Quality Check


Label Check

Final calibration & test


incoming receipts

Assembly & Quality Checklist

CM-19-03-012

Start traveler &


Note: Green accepted labels will be applied to subassemblies at specified workstations when they pass the go/no-go test and inspection.


Build pH Chamber7756-1115


Brine Tank assembly

7756-1106

Jet Pump & Waste Tank

assembly7756-1108

Assemble Boardsto Electric Plate

PeristalticPump

Assembly7756-1117


Package UnitQuality Assurance Checklist Review

Sign traveler

Build Cell Pack

7756-1113

Build Outlet assembly

7756-1126

Build Inlet assembly

7756-1109

Build conductivity probe7756-1116

Build Catholyte Chamber7756-1114

Remote programmingport

7756-1118

Tubing7756-1129

U/I assembly7756-1124

Cover assembly7756-1102

Labeling7756-1102

Supervisor OK to ship CheckSign traveler

Sterilox tank & sensor

7756-1107



CM-19-03-010 Rev A

CM-19-01-002 Rev A

Fitting Leak 59Assembly Defect 37pH Control Failure 33Conductivity Control Failure 18Tank Leak 11SV-7 no/too little flow 7

Conductivity Probe 10pH Probe 1CPU 5Inoperable 20

Incorrect assembly 13Sensor not secure 7Loose Connections 5Damaged/malfunctioned component 5Sensor incorrect location 3Other 3

1st 100 Build Overall Defect Pareto Analysis

59

37 33

1811 7

010203040506070

Fitti

ng L

eak

Asse

mbl

yD

efec

t

pH C

ontro

lFa

ilure

Con

duct

ivity

Con

trol

Failu

re

Tank

Lea

k

SV-7

no/

too

little

flow

# of

Occ

urre

nces

1st 100 Build Assembly Defect Pareto Analysis

13

75 5

3 3

02468

101214

Inco

rrec

t ass

embl

y

Sens

or n

ot s

ecur

e

Loos

e C

onne

ctio

ns

Dam

aged

/mal

func

tion

ed c

ompo

nent

Sens

or in

corr

ect

loca

tion O

ther

# of

Occ

urre

nces

Transition from DMADV to DMAICPre-Production Build & Evaluation

FMEA using Final Test Data

Service History

Compare data to determine product & cell design changes(can establish ratios)

Customer feedback

Pre-Production Cell Design & Flow to Eliminate the Eight Wastes

Pre-Production Cell Design & Flow to Eliminate the Eight Wastes

Inventory (more than one piece flow)Inventory (more than one piece flow)Overproduction (more or Overproduction (more or soonersooner than needed)than needed)Correction (inspection and rework)Correction (inspection and rework)Material MovementMaterial MovementWaitingWaitingMotionMotionNonNon--Value Added ProcessingValue Added ProcessingUnderutilized PeopleUnderutilized People

Changes to Cell Design from Quality & Service Data

Reduce Defects & Cycle Time

Changes to Cell Design from Quality & Changes to Cell Design from Quality & Service DataService Data

Reduce Defects & Cycle TimeReduce Defects & Cycle Time

Change design & method of connecting piping Change design & method of connecting piping fittings & pressure testing to eliminate leaks & fittings & pressure testing to eliminate leaks & reduce cycle timereduce cycle time

Simplified final test procedure through improved Simplified final test procedure through improved conductivity controlconductivity control

Simplified waste tank assemblySimplified waste tank assembly

Vendor to supply wire harnessesVendor to supply wire harnesses

Product & Cellular Design Continue Product & Cellular Design Continue in Parallelin Parallel

Cellular Assembly Verification

Cellular Concepts

Define & Measure

Design• Requirements

• FMEA

Analyze• Concepts


• Drawings & BOM

DMAICCycle

Cellular Flow, Sequence, Layout

Pre-ProductionCell

Cell Requirements

After DMADV: the DMAIC CycleAfter DMADV: the DMAIC Cycle

Define

ImprovePlan-Do-Study-Act

Measure &Analyze

Control

Plan-Do-Study-ActTeamsBenchmarkAnalysis toolsID variability

Employee Involvement

Design of Experiments

SDCASDCA

SDCASDCA

SDCA = StandardizeSDCA = Standardize--DoDo--CheckCheck--AdjustAdjust

Six Sigma In ActionSix Sigma In Action

Lessons LearnedLessons LearnedSpecify everything: Specify everything: fasteners, tube lengths, fasteners, tube lengths, etc. (or the assemblers will etc. (or the assemblers will guess)guess)Avoid tight fits. Watch Avoid tight fits. Watch stack up tolerancesstack up tolerancesUnderstand vendor Understand vendor capabilitiescapabilitiesHave vendors supply Have vendors supply complete subassembliescomplete subassembliesNeed to verify BOMs at Need to verify BOMs at each workstationeach workstationHave assemblers Have assemblers participate in prototype participate in prototype assemblyassembly

Designing Products for Lean Cellular AssemblyDesigning Products for Lean Cellular Assembly

Operating costs

Process speed(lead time)

Inventory & invested capital

Quality

Customer satisfaction

Operating flexibility

Methodology that Methodology that maximizesmaximizes value and value and achieves achieves improvementimprovement inin……....

Contact InformationContact Information

Advent Design CorporationAdvent Design CorporationCanal Street and Jefferson Ave.Canal Street and Jefferson Ave.

Bristol, PA 19007Bristol, PA 19007

www.adventdesign.comwww.adventdesign.com800800--959959--03100310

Frank Garcia, Director Engineering ServicesFrank Garcia, Director Engineering [email protected]@adventdesign.com

Thomas A. Lawton, PresidentThomas A. Lawton, [email protected]@adventdesign.com

Advent Design Corporation

925 Canal StreetBristol PA, 19007

(P) 215 781 0500(F) 215 781 0508

Bill Chesterson

Tom Lawton

Frank Garciawww.adventdesign.com

CEO Automation & Product Design215 781 0500 Ext: [email protected]

PresidentContract Manufacturing215 781 0500 Ext: [email protected]

DirectorPlanning & Productivity215 781 0500 Ext: [email protected]

designing products for cellular assembly

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