Origami Production ProjectOrigami Production Project

The Angel & The DinosaurThe Angel & The Dinosaur

Objectives of ProjectObjectives of Project

Simulate a production activity (in Etcheverry Simulate a production activity (in Etcheverry 4193)4193)

Learn a little bit about many relevant IEOR Learn a little bit about many relevant IEOR concepts covered in later coursesconcepts covered in later courses

Gain experience in teamwork and report Gain experience in teamwork and report writingwriting

Have fun competing with your peersHave fun competing with your peers Do something usefulDo something useful

Use of ProductUse of Product

The product will be The product will be given to children in given to children in hospitals.hospitals.

Teams are asked to Teams are asked to write personal notes of write personal notes of encouragement on the encouragement on the bottoms of the origami bottoms of the origami objects.objects.

(In-class) Competition Dates(In-class) Competition Dates

FridayFriday, December 9, December 9 GSI office hour:GSI office hour:

– Tuesday (Dec 6) from 12:00-1:00 at 1171 Tuesday (Dec 6) from 12:00-1:00 at 1171 Etcheverry (DECF computer lab) Etcheverry (DECF computer lab)

The project emphasizes: QualityThe project emphasizes: Quality

CompetitionCompetition

ProductivityProductivity

TeamworkTeamwork

Real-World ParallelsReal-World Parallels

Everything you do in this project is either the Everything you do in this project is either the same as, or closely parallels, things you same as, or closely parallels, things you would do in a real manufacturing project.would do in a real manufacturing project.

The principal difference is the scale of the The principal difference is the scale of the project – not the content.project – not the content.

What are the Origami Objects?What are the Origami Objects?

AngelAngel

DinosaurDinosaur

How to make the objectsHow to make the objects

Go to the web sites Go to the web sites

http://dev.origami.com/images_pdf/angel_fehl.http://dev.origami.com/images_pdf/angel_fehl.pdfpdf

http://dev.origami.com/images_pdf/ptrex.pdfhttp://dev.origami.com/images_pdf/ptrex.pdf Read the instructions – also see handout.Read the instructions – also see handout.

Project DescriptionProject Description

Teams of four or five will have 5+5 minutes Teams of four or five will have 5+5 minutes to produce angel & dinosaur origami models to produce angel & dinosaur origami models from square sheets of paper. Team from square sheets of paper. Team assignments have already been made.assignments have already been made.

Project RulesProject Rules

Teams can “buy” provided paper in four ways -Teams can “buy” provided paper in four ways -

1.1. Bulk pack (10 sheets) uncut (8 ½ x 11) Bulk pack (10 sheets) uncut (8 ½ x 11) $4 /sheet $40 /pack$4 /sheet $40 /pack

2.2. Pair uncut (8 ½ x 11)Pair uncut (8 ½ x 11)$6 /sheet $12 /pair$6 /sheet $12 /pair

3.3. Bulk pack (10 sheets) precut (square)Bulk pack (10 sheets) precut (square)$7 /sheet $70 /pack$7 /sheet $70 /pack

4.4. Pair precut (square)Pair precut (square)$9 /sheet $18 /pair$9 /sheet $18 /pair

Note that you can only make objects from 8 ½ x 8 ½ size Note that you can only make objects from 8 ½ x 8 ½ size paper. paper. Nothing smaller will be acceptedNothing smaller will be accepted

Example PaperExample Paper

Wage ChargesWage Charges

Wages will be charged per person per 5 Wages will be charged per person per 5 minute periodminute period

1.1. Quality standard setting time: for the first 5 Quality standard setting time: for the first 5 minutes - $4/person/5 minutesminutes - $4/person/5 minutes

2.2. Regular time: for the next 5 minutes - $4 Regular time: for the next 5 minutes - $4 /person /5 minutes/person /5 minutes

3.3. Overtime: for the next 5 minutes - $8 Overtime: for the next 5 minutes - $8 /person /5 minutes/person /5 minutes

Quality Standard Setting Time Quality Standard Setting Time Each team will have 5 minutes before the main production time to make 3 Each team will have 5 minutes before the main production time to make 3

PERFECT dinosaurs and 1 PERFECT angelPERFECT dinosaurs and 1 PERFECT angel PenaltyPenalty

– All 4 perfect: no penaltyAll 4 perfect: no penalty– 3 perfect: $15 penalty3 perfect: $15 penalty– 2 perfect: $30 penalty2 perfect: $30 penalty– 1 perfect: $45 penalty1 perfect: $45 penalty– 0 perfect: $60 penalty0 perfect: $60 penalty

Objects made in this period is NOT for sale. In other words, they will not be Objects made in this period is NOT for sale. In other words, they will not be counted in the total countcounted in the total count

Waste DisposalWaste Disposal

Disposal FeesDisposal Fees

Teams having extra strips from trimming Teams having extra strips from trimming their own paper must pay disposal fees. their own paper must pay disposal fees. The first 20 strips will not be charged for. The first 20 strips will not be charged for. Waste management will then charge $1/strip Waste management will then charge $1/strip after 20. after 20.

The fee will be calculated by using the total The fee will be calculated by using the total number of 8 ½ x 11 sheets bought, so even number of 8 ½ x 11 sheets bought, so even uncut 8 ½ x 11 sheets will be subjected to uncut 8 ½ x 11 sheets will be subjected to the fee.the fee.

Poor Quality Disposal FeePoor Quality Disposal Fee

A $1/unit charge will also be applied to all A $1/unit charge will also be applied to all models not bought because of unacceptable models not bought because of unacceptable quality. quality.

Your paper supplier will not accept returns. Your paper supplier will not accept returns. Once you buy the paper, it’s yours.Once you buy the paper, it’s yours.

Selling PricesSelling Prices

Selling price is $20/unit for each dinosaur, Selling price is $20/unit for each dinosaur, and $40/unit for each angel.and $40/unit for each angel.

The selling price is reduced by $5 for each The selling price is reduced by $5 for each defect down to half price for both the defect down to half price for both the dinosaur and the angeldinosaur and the angel

– – and then to zero.and then to zero.

Assume you can sell everything of Assume you can sell everything of acceptable quality you can make.acceptable quality you can make.

Production ConsiderationsProduction Considerations

Production: Production:

1.1. Paper may be stacked for cutting; however, Paper may be stacked for cutting; however, great care must be taken to get a square cut. great care must be taken to get a square cut. Uneven cuts result in defects. Uneven cuts result in defects.

2.2. Teams choose their own production method. Teams choose their own production method. Some methods are more productive than others; Some methods are more productive than others; it pays off to spend the time to find a good one. it pays off to spend the time to find a good one. In addition, not all team members must work for In addition, not all team members must work for the entire 15 minutes. the entire 15 minutes.

More Production ConsiderationsMore Production Considerations

1.1. Teams must Teams must produce a high quality produce a high quality productproduct by making sharp, even folds. Any by making sharp, even folds. Any angel or dinosaur of unacceptable quality angel or dinosaur of unacceptable quality will not be bought.will not be bought.

2.2. Teams need not follow the origami Teams need not follow the origami instructions exactly, but instructions exactly, but their product their product should be just as goodshould be just as good as ones made by as ones made by following the instructions (design for following the instructions (design for manufacturability). manufacturability).

Quality Warning!!!!!Quality Warning!!!!!

Past experience indicates Past experience indicates that the biggest difficulty that the biggest difficulty teams have is teams have is

makingmaking

a higha high

qualityquality

product!product!

Typical Quality ProblemsTypical Quality Problems

Poor foldsPoor folds

Lack of symmetryLack of symmetry

Extra bends in paperExtra bends in paper

Failure to follow folding instructionsFailure to follow folding instructions

Quality ControlQuality Control

Each team will have a Each team will have a Quality Control Quality Control Inspector (QCI).Inspector (QCI).

The QCI willThe QCI will

1.1. compare each origami object with a gage-compare each origami object with a gage-standard object, and write the number of standard object, and write the number of defects on the object;defects on the object;

2.2. sign a quality statement certifying each sign a quality statement certifying each object was compared to the standard and object was compared to the standard and all defects were noted;all defects were noted;

3.3. be assisted by the production team in be assisted by the production team in sorting the objects by defect count (0,1,2,sorting the objects by defect count (0,1,2,(3,4), scrap);(3,4), scrap);

The QCIThe QCI

1.1. and the production team will have 5 and the production team will have 5 minutes after final assembly to inspect and minutes after final assembly to inspect and sort finished goods – any remaining sort finished goods – any remaining objects count as scrap;objects count as scrap;

2.2. may participate in fabrication or inspection may participate in fabrication or inspection during fabrication; time is charged at the during fabrication; time is charged at the same rate as the fabricators.same rate as the fabricators.

“free”

Customer Quality AuditCustomer Quality Audit

The instructors will perform The instructors will perform a customer quality audit at a customer quality audit at the end of the 10-minute the end of the 10-minute QC and sort period.QC and sort period.

Any finished goods with Any finished goods with more defects than more defects than recorded by the QCI will be recorded by the QCI will be subject to a $10/piece non-subject to a $10/piece non-conformance quality conformance quality penalty.penalty.

Production HintsProduction Hints

Hints: Hints: Adequate time will be given to plan Adequate time will be given to plan for the project. Start early by practising for the project. Start early by practising making the models. Once the learning making the models. Once the learning curve is negligible, curve is negligible, think about the most think about the most efficient way to set up your production efficient way to set up your production methodmethod. .

Next, look at your costs, and Next, look at your costs, and think of ways think of ways to modify your assemblyto modify your assembly after certain points after certain points in production. in production.

Product Mix DecisionProduct Mix Decision

An angel sells for more than a dinosaur, An angel sells for more than a dinosaur, but its unit production time is slightly but its unit production time is slightly greater than that of a dinosaur and it is greater than that of a dinosaur and it is hard to make an angel with no defects. hard to make an angel with no defects. Thus, your company has a Thus, your company has a product mix product mix decisiondecision: to decide on the number of each : to decide on the number of each type of unit to produce.type of unit to produce.

Raw Material Purchase DecisionsRaw Material Purchase Decisions

Buying uncut paper is cheaper. However, Buying uncut paper is cheaper. However, once waste management starts charging once waste management starts charging you for disposal of the strips, you may you for disposal of the strips, you may want to consider buying the paper precut. want to consider buying the paper precut.

Buying in Bulk, Disposal ChargesBuying in Bulk, Disposal Charges

Similarly, buying paper in bulk is cheaper Similarly, buying paper in bulk is cheaper than buying it in pairs. than buying it in pairs.

However, since paper unused at the end of However, since paper unused at the end of production has no rate of return and is production has no rate of return and is subject to disposal fees, teams may want subject to disposal fees, teams may want to buy it in pairs towards the end of the to buy it in pairs towards the end of the time limit. time limit.

WagesWages

Overtime WagesOvertime Wages

Since wages increase up to double in Since wages increase up to double in overtime, teams should look at their overtime, teams should look at their revenues and costs carefully at this stage, revenues and costs carefully at this stage, since profits will decline sharply and could since profits will decline sharply and could even turn to losses. even turn to losses.

Wage ChargesWage Charges

Wages are charged on a 5 minute basis. Wages are charged on a 5 minute basis. A team member who stops working after 8 A team member who stops working after 8 minutes will still be charged for 10 minutes.minutes will still be charged for 10 minutes.

Winning is SweetWinning is Sweet

The team making the The team making the most profit per team most profit per team member wins the member wins the competition, and competition, and receives a special receives a special certificate. certificate.

Your team may win!Your team may win!

GradingGrading

1.1. 25% is based on profit per team member25% is based on profit per team member

2.2. 65% is based on the written project65% is based on the written project

3.3. 10% is based upon professionalism—10% is based upon professionalism—individual and team grades may be individual and team grades may be impacted by professionalism impacted by professionalism transgressionstransgressions

Origami Day: Big PictureOrigami Day: Big Picture

1)1) Paper is provided (teams may bring own Paper is provided (teams may bring own scissors instead of renting them. Rulers may be scissors instead of renting them. Rulers may be used for any purpose).used for any purpose).

2)2) We take time in class to get set up.We take time in class to get set up.3)3) We have the quality standard setting period.We have the quality standard setting period.4)4) We set up for the regular time period.We set up for the regular time period.5)5) We have the regular time production period.We have the regular time production period.6)6) We set up for overtime.We set up for overtime.7)7) We have the overtime period.We have the overtime period.

Origami Day: Big PictureOrigami Day: Big Picture

1)1) QC and sort period for 5 minutes.QC and sort period for 5 minutes.

2)2) Buyers decide which products to buy, Buyers decide which products to buy, based on quality, and make purchases.based on quality, and make purchases.

3)3) We complete team accounting forms.We complete team accounting forms.

4)4) Team productivity data is displayed on Team productivity data is displayed on board or electronically.board or electronically.

5)5) A most profitable team is determined.A most profitable team is determined.

Report OrganizationReport Organization

cover page with title, date, names of cover page with title, date, names of authors, and pledge signed by all authors - authors, and pledge signed by all authors - reports without signatures will not be gradedreports without signatures will not be graded

executive summary: a brief synopsis of executive summary: a brief synopsis of report contents (no more than half a page)report contents (no more than half a page)

table of contentstable of contents explanation of the activityexplanation of the activity how your team analyzed the problem and how your team analyzed the problem and

prepared for the competitionprepared for the competition

Report OrganizationReport Organization

What you learned from this project?What you learned from this project? How can you do better next time?How can you do better next time? your evaluation of the competition; its your evaluation of the competition; its

plusses and minusesplusses and minuses

Concepts to Explain w. ProjectConcepts to Explain w. Project

1)1) Bill of materialsBill of materials

2)2) Process flowsProcess flows

3)3) LayoutLayout

4)4) Line balancing and assembly methods Line balancing and assembly methods

5)5) Work DesignWork Design

6)6) Total Quality Management & Quality ControlTotal Quality Management & Quality Control

7)7) Jigs, fixtures, special toolsJigs, fixtures, special tools

8)8) Design for manufacturabilityDesign for manufacturability

Concepts to Explain w. ProjectConcepts to Explain w. Project

1)1) Product reworkProduct rework

2)2) Product mixProduct mix

3)3) Learning/startup effectLearning/startup effect

4)4) Regular time versus overtime productionRegular time versus overtime production

5)5) Inventory: raw material, in-process, finished goodsInventory: raw material, in-process, finished goods

6)6) Cost accountingCost accounting

7)7) Job enrichmentJob enrichment

8)8) Dealing with suppliers, and dealing with customersDealing with suppliers, and dealing with customers

9)9) Reverse engineeringReverse engineering

Report Due DateReport Due Date

Friday, November 11, 4 PM.Friday, November 11, 4 PM.

Leave the report (the exam) in my mailbox.Leave the report (the exam) in my mailbox.

Late reports receive a grade of zero.Late reports receive a grade of zero.

SummarySummary

We emphasizeWe emphasize– QualityQuality– CompetitionCompetition– Report WritingReport Writing– Productivity Productivity – TeamworkTeamwork– ProfessionalismProfessionalism

A Last WordA Last Word

We are We are notnot trying to trying to make you Origami make you Origami experts. experts.

We are trying to We are trying to introduce you, in an introduce you, in an interesting way, to interesting way, to concepts you will learn concepts you will learn more about in follow-more about in follow-on courses.on courses.