Improving Process Efficiency Lou-Rich, Inc. Carter Tollefson - - PowerPoint PPT Presentation

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Improving Process Efficiency Lou-Rich, Inc. Carter Tollefson - - PowerPoint PPT Presentation

Sep 11, 2022 223 likes •494 views

Improving Process Efficiency Lou-Rich, Inc. Carter Tollefson Advisor: Jon Vanyo Company Supervisor: Lee Gulbrandson Company Overview Contract engineering and manufacturing Based in Albert Lea, MN Provides services to original

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SLIDE 1

Improving Process Efficiency

Lou-Rich, Inc.

Carter Tollefson

Advisor: Jon Vanyo Company Supervisor: Lee Gulbrandson

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SLIDE 2

Company Overview

  • Contract engineering and manufacturing
  • Based in Albert Lea, MN
  • Provides services to original equipment manufacturers (OEMs) in

ag., medical device, food service, and many more

  • Services include: engineering design for manufacturing services,

material sourcing, welding, assembling, testing, CNC machining, fabrication, powder/liquid coatings, assembly, aluminum extrusions

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SLIDE 3

Albert Lea

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SLIDE 4

Process Description

  • 5 different freezers made – all follow similar processes
  • Components (coils, flanges, and tubes) made
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SLIDE 5

Process Continued

  • Washed
  • Welding tube and flange
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SLIDE 6

Process Continued

  • Soldering coil to tube
  • *Base and inlet welding
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SLIDE 7

Process Continued

  • Machining Processes
  • Foaming
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SLIDE 8

Incentives to Change

  • Commitment to process improvement
  • Investigate process efficiency opportunities
  • Source reduction opportunities in washing system
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SLIDE 9

Reasons for MnTAP Assistance

  • Investigate/implement lean opportunities
  • Look for opportunities to improve operator processes
  • Determine opportunities for chemical and water savings
  • Reduction of inventory in work cells
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SLIDE 10

Approach

  • Monitored and gained understanding of processes
  • Documented own ideas for improvement
  • Held brainstorming sessions and documented ideas for

improvement

  • Identified the types of waste and where is it was occurring
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SLIDE 11

Determining Solutions

  • Timed processes
  • Value-stream maps
  • Spaghetti diagrams
  • Consulting with companies
  • Reviewed observations and notes
  • Meetings with staff and operators
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SLIDE 12

Current Layout and Part Movement

  • Opportunities
  • Excess movement taking parts to and from work cells
  • Loading time onto carts and machines
  • Solutions
  • Implement conveyor system between work cells
  • Change equipment orientation and locations
  • Savings
  • ~260 hrs/year  $7,100/year
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SLIDE 13

Washer Location

Washer Conveyor Cone yor Unload Bay HOOK COVERAGE ON HOIST OEC Cart Scale HOOK COVERAGE ON HOIST Rack Rack Load Bay OEC Cart OEC Cart OEC Cart OEC Cart Cardboard Rack Pack Out Table Bubble Foam Hooks Hooks Incoming Lane OK to Ship 16 Supply Cabinet WASHER Resistance Solder Water Heater Old Relic Work Bench Washer Inspection Table In Feed Table Water Pump Water Main Post Power Brake Pad Assembly OEC Cure Oven OEC Copper Tube Rack Straightener Copper Coil Unload Table Coil Super Marke t Coil Super Marke t Long Coils Short Coils Short Coils Electrical Panel Tank Heated Rinse Tank Rinse Venting and Plumbing for tanks Tank Rinse Tank Rinse Tank Soap Tank Prepare Elec Panel Fixtures Small Parts Tank with Vent & Heat Tank Tank Tank Cart Cart Solder Station Gas Tanks Test Tank Nitro Tank Drain Washer Fluid Cabinet Cabinet Chip Hopper Electrical Burnisher S e r r a t e r T a p D P Spout DP Count er Sink Debur Station Counter Sink DP Burnisher 8 Hole Natco DP Work Bench Profilometer Rack Rack Rack Foam Dies Storage Rack for Foam Tubes Water Leak Tester Work Bench Foamer Foamer Foamer SS Freezer Cart Freezer Rack Boxes For Shipping Packaging Supplies Packaging Supplies Boxes For Shipping Foamer Pump Foamer Foamer SS Freezer Cart Freezer Rack Freezer Rack Cleaning Station Work Bench Raw Saw Cut Tubes Raw SS Drilling Station Work Bench Chip Hopper Electrical Chip Hopper Electrical Tool Chest Work Bench Base Flange Superma rket Tubes Tubes Tubes Tubes Tubes Tube Superma rket Coil Base Flange Superma rket Raw SS Conveyor Tig Station Tig Welder Elec Panel Rinses Welding Fixtures Tool Chest Solder Mounts Long Coils Cart Cabinet Freezer Rack Freezer Rack Freezer Rack Freezer Rack Tubes SS Freezer Cart SS Freezer Cart SS Freezer Cart Freezer Table SS Freezer Cart SS Freezer Cart Work Bench Elec Panel Solder Tank Fan Solder Station Inline Fluxer Torch Tanks Table Drai n Grat e
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SLIDE 14

Current Layout

Washer Conveyor Cone yor Resistance Solder Water Heater Old Relic Work Bench Washer Inspection Table In Feed Table Water Pump Water Main Post Power Brake Pad Assembly OEC Cure Oven OEC Copper Tube Rack Straightener Copper Coil Unload Table Coil Super Marke t Coil Super Marke t Long Coils Short Coils Short Coils Electrical Panel Tank Heated Rinse Tank Rinse Venting and Plumbing for tanks Tank Rinse Tank Rinse Tank Soap Tank Prepare Elec Panel Fixtures Small Parts Tank with Vent & Heat Tank Tank Tank Cart Cart Solder Station Gas Tanks Test Tank Nitro Tank Drain Washer Fluid Cabinet Cabinet Chip Hopper Electrical Burnisher S e r r a t e r T a p D P Spout DP Count er Sink Debur Station Counter Sink DP Burnisher 8 Hole Natco DP Work Bench Profilometer Rack Rack Rack Foam Dies Storage Rack for Foam Tubes Water Leak Tester Work Bench Foamer Foamer Foamer SS Freezer Cart Freezer Rack Boxes For Shipping Packaging Supplies Packaging Supplies Boxes For Shipping Foamer Pump Foamer Foamer SS Freezer Cart Freezer Rack Freezer Rack Cleaning Station Work Bench Raw Saw Cut Tubes Raw SS Drilling Station Work Bench Chip Hopper Electrical Chip Hopper Electrical Tool Chest Work Bench Base Flange Superma rket Tubes Tubes Tubes Tubes Tubes Tube Superma rket Coil Base Flange Superma rket Raw SS Conveyor Tig Station Tig Welder Elec Panel Rinses Welding Fixtures Tool Chest Solder Mounts Long Coils Cart Cabinet Freezer Rack Freezer Rack Freezer Rack Freezer Rack Tubes SS Freezer Cart SS Freezer Cart SS Freezer Cart Freezer Table SS Freezer Cart SS Freezer Cart Work Bench Elec Panel Solder Tank Fan Solder Station Inline Fluxer Torch Tanks Table Drai n Grat e
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SLIDE 15

Proposed Layout

Foamer Raw Saw Cut Tubes Water Heater Inspection Table In Feed Table Water Pump Water Main Post Power Raw SS Drilling Station Work Bench Electrical Panel Tank Heated Rinse Tank Rinse Venting and Plumbing for tanks Tank Rinse Tank Rinse Tank Soap Tank Prepare Elec Panel Fixtures Small Parts Tank with Vent & Heat Tank Tank Tank Cart Cart Solder Station Gas Tanks Test Tank Nitro Tank Drain Work Bench Elec Panel Solder Tank Rack Rack Rack Packaging Supplies Packaging Supplies Pump Chip Hopper Electrical Short Coils Chip Hopper Electrical Chip Hopper Electrical Rinses Welding Fixtures Cabinet Cabinet Cabinet Tool Chest Tool Chest Solder Mounts Walkway Rinser Work Bench Conveyor Move able Table Cabinet Conveyor Foam Dies Storage Rack for Foam Tubes Water Leak Tester Work Bench Foamer Foamer Foamer Freezer Rack Boxes For Shipping Boxes For Shipping Foamer Foamer Cabinet Tool Chest Cabinet Tool Chest Solder Station Inline Fluxer Torch Tanks U-Shaped Washer Copper Tube Rack Straightener Copper Coil Unload Table Coil Coil Two way-Conveyor Tig Station Tig Welder Elec Panel Cleaning Station Work Bench Raw Saw Cut Tubes Raw SS

Proposed Scotsman Layout

Burnisher Serrater Tap DP Spout DP C
  • u
n t e r S i n k Debur Station Counter Sink DP Burnisher 8 Hole Natco DP Work Bench Profilometer Washer Conveyor Conve yor Grat e Double Conveyor with Bases and Flanges Coils Tubes Flanges + Bases
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SLIDE 16

Spaghetti Diagrams

Current Movement Proposed Movement

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SLIDE 17

Coiling and Foaming Processes

  • Opportunities
  • Inventory build up between process steps (non value adding time)
  • Excess inventory
  • Waiting
  • Order of operations efficiency
  • Solutions
  • Creation of standard work documents
  • Training and explanation to operators
  • Savings
  • ~420 hrs/year  $11,500/year
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SLIDE 18

Current State Part Washing Process

  • Coil Washer
  • Not performing up to washing standards
  • Chemical and water go straight to drain after one cycle
  • Hallway Washer
  • Wash, Rinse, Blow off
  • Operators paid to load and unload parts
  • Parts from different areas washed in same washer
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SLIDE 19

Proposed Improvements

  • Remove coil washer
  • Power, water, and chemical savings
  • No chemical and water being wasted
  • Purchase New Washer and Place in Freezer Area
  • Dual-rinse and overflow system to conserve water and reduce operator

attention

  • U-shaped design
  • Current operators will be reassigned
  • No waiting for non-freezer parts
  • Elimination of forklifts and operator time transporting parts
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SLIDE 20

Improvement Savings

  • Savings

Coil Washer

  • ~1,270 kWh/year  $100/year
  • ~19,200 gal/year  $120/year
  • Chemicals - 866 gal/year  $13,000/year

New Washer

  • ~280 hrs/year  $7,700/year
  • ~29,300 gal/year  $180/year
  • Not using forklifts  $1,750/year
  • Not paying operators  $2,550/year
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SLIDE 21

Part and Finished Product Storage

  • Opportunity
  • Large amount of inventory between work cells (space, $)
  • Trouble adjusting to order fluctuations (change-overs, shipping dates, part

moving and storage)

  • Distance and time to bring components needed to assembly areas
  • Solution
  • Install finished goods supermarket (buffer for changes)
  • Part supermarket (ordered and proximity to cells)
  • Pull system based on demand rather than push based on predictions
  • Savings
  • ~50 hrs/year  $1,400/year
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SLIDE 22

Recommended Changes

Recommendation Water (gpy) Operators (hrs/year) Net savings ($/year) Implementation cost Payback period Status Layout and Conveyor System 260 $7,100 $5,000 8.5 months Proposed Implement Standard Work 420 $11,500 Immediate Implemented Implement New Washer 29,300 280 $12,180 $130,000 10.8 years Proposed Remove Coil Washer 19,200 $13,220 $500 13 days Proposed Implement Supermarkets 50 $1,400 $1,000 8.7 months Proposed Totals 48,500 1010 $45,400 $136,500 ~3 years

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SLIDE 23

Additional/Possible Future Projects

  • Compressed Air System
  • Opportunity
  • Air leaks and processes
  • Solution
  • Documentation of usage at in

each area

  • Ultrasonic leak tester to detect

leaks on fixtures

  • Rinse Water Disposal
  • Opportunity
  • $2.50/lb to dispose of water

which was $26,000 over last 2 months

  • Solution
  • Water treatment system
  • Evaporator
  • Change flux type
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SLIDE 24

Personal Benefits

  • Real-world experience and application of education
  • Knowledge of lean manufacturing principals
  • Independent learning
  • Communication with operators and staff
  • Communication with other companies
  • Teamwork
  • Cost/benefit analysis
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SLIDE 25

Questions?