““IMPROVING THE IMPROVING THE PRODUCTIVITY OF THE PRODUCTIVITY OF THE

HIGH-VOLUME MULTI-WORK HIGH-VOLUME MULTI-WORK CELL MILLING PROCESS AT CELL MILLING PROCESS AT

THE AMERICAN SAW THE AMERICAN SAW COMPANY”COMPANY”

Senior Project Proposal Presented By:Senior Project Proposal Presented By:

Mark RumbutisMark Rumbutis

And And

Katie JonesKatie Jones

Advisor: Dr. William BrownAdvisor: Dr. William Brown

Overview of PresentationOverview of Presentation

Company HistoryCompany History Definition of ProblemDefinition of Problem Stacey Milling Machine VideoStacey Milling Machine Video Approaches to ProblemApproaches to Problem Deliverables of ProjectDeliverables of Project Initial WorkInitial Work Stacey Milling Machine Flow ChartStacey Milling Machine Flow Chart Microsoft Project ScheduleMicrosoft Project Schedule QuestionsQuestions

Company HistoryCompany History

American Saw & Mfg. Company began in 1915American Saw & Mfg. Company began in 1915 On January 6, 2003 Newell Rubbermaid completed the On January 6, 2003 Newell Rubbermaid completed the

acquisition of the American Saw Companyacquisition of the American Saw Company Employs over 600 people in over 70 countries around Employs over 600 people in over 70 countries around

the world the world Despite the considerable changes over time, the Despite the considerable changes over time, the

LENOX® trade name has remained constantly LENOX® trade name has remained constantly

synonymous with qualitysynonymous with quality

Definition of ProblemDefinition of Problem

This project focuses on approaches to improve This project focuses on approaches to improve productivity on the Stacey Milling Machines productivity on the Stacey Milling Machines

Focus will be on improving the internal Milling Focus will be on improving the internal Milling Machine Process Machine Process

Improving the consistency of the procedures by Improving the consistency of the procedures by standardizing the process standardizing the process

Inconsistency and variance of procedure results Inconsistency and variance of procedure results in lost timein lost time

Stacey Milling Machine VideoStacey Milling Machine Video

Approaches to ProblemApproaches to Problem

Digitally recorded the milling process to Digitally recorded the milling process to determine time standardsdetermine time standards

Time studies using a stop watch to Time studies using a stop watch to determine standard work measurementsdetermine standard work measurements

Creating a computer simulation of the Creating a computer simulation of the process using Taylor EDprocess using Taylor ED

Define and analyzing the problem using the Define and analyzing the problem using the Magnificent Seven Tools Magnificent Seven Tools

Deliverables of ProjectDeliverables of Project

Provide standard set up and operating Provide standard set up and operating procedures procedures

Financial ImpactFinancial Impact A solution that will be implemented by A solution that will be implemented by

LENOX®LENOX® Saw – Win/Win/Win Saw – Win/Win/Win ABET 8ABET 8

Economic Concerns and ImplicationsEconomic Concerns and Implications SustainabilitySustainability ManufacturabilityManufacturability Health and Safety Concerns and ImplicationsHealth and Safety Concerns and Implications Social Concerns and ImplicationsSocial Concerns and Implications

Initial Work Initial Work

Project Status as of December 15, 2003Project Status as of December 15, 2003 Defining VariablesDefining Variables

Milling CutterMilling Cutter Work ViceWork Vice Stack HeightStack Height Leveling KnifeLeveling Knife

Video TapingVideo Taping Determined for time studiesDetermined for time studies

Developed Flow ChartDeveloped Flow Chart Project Plan EstablishedProject Plan Established

Stacy Milling Machine Flow ChartStacy Milling Machine Flow Chart

Cycle Flowchart of the Stacy Milling Machines Located atthe American Saw Company

Wedge moves,cutter is

hydraulicallydrawn upward

Cutting ofstacked material

begins

Cutting ofstacked material

is completed

Work vice opensTransfer vice

slides stackedmaterial

Leveling Knifelevels stacked

material

Work vice shutscompressing thestacked material

Cutting is inprocess

Transfer viceslides back andcompresses thestacked material

* The preceding flowchart is a rough draft. As more is learned, the cycle willchange.

Figure 1. Flow Chart for Stacy Milling Machine Cycle Time.

Microsoft Project Schedule Microsoft Project Schedule

Questions?Questions?