Nicki Ripperda Internship Portfolio

Manufacturing Engineering 2015

2

Process Mapping

Curtain Machine Production Line

Draft Map

Final Map

CNC

Purchased

FabElectronics

Assembly

3

Sample Part

New Machine Setup

Haeger Hardware Insertion Machine– Develop machine settings for different hardware studs and psi settings for material thickness– Selection of upper and lower tooling with development of a parts matrix

Stud Top Tool Bottom Tool PSI SettingS-7436 H-108-0020L H-109-6/m3.5l 1,200S-6962 H-108-0020L H-103-05L 1,700S-4330 H-108-0020L H-103-04L 1,700

Part Number Stud Additional Tool PSI273000 S-4330 11361-1 1,700

Special Tools

4

Time Study

Drive Unit Gearbox and Motor Assembly

Station VA NVA Total Time (sec)Shaft Assy (St. 1 & 2) 30 0 30Gearbox Housing (St. 3, 4, &5) 103.5 0 103.5Shaft Sub Assy (St. 6) 10.67 0 10.67Gearbox Shaft (St. 7) 7.5 0 7.5Gearbox Plate (St. 8) 8.57 0 8.57Gearbox Assy. (St. 9) 81.333 3.5 84.833Motor Assy. (St. 10) 155.2 2 157.2Packaging (St. 11) 147.83 20 167.83

570.103

Shaft A

ssy (

St. 1 &

2)

Gearbo

x Hou

sing (

St. 3, 4

, &5)

Shaft S

ub A

ssy (

St. 6)

Gearbo

x Sha

ft (St. 7

)

Gearbo

x Plat

e (St. 8

)

Gearbo

x Ass

y. (S

t. 9)

Motor A

ssy.

(St.

10)

Packa

ging (

St. 11)

0

20

40

60

80

100

120

140

160

180

30

103.5

10.67 7.5 8.57

81.333

155.2147.83

0

0

0 0 0

3.5

2 20

VA vs. NVA

Nonvalue AddedValue Added

Station

Tim

e (s

ec)

Drive Unit with Gearbox

5

Standard Work

Taking Time Study Information– Calculate TAKT time

– Calculate ideal number of operators – Develop current state standardized work– Align process steps to develop new layout

– Present layout changes, crew planning and standard work changes

Current Process Proposed Process

6

Work Instruction

Develop Work Instruction for Flex Auger Production– Training tool for new associates– Standardized practice to reduce

– Operator variation– Safety checkpoints– Quality checkpoint

Step No.

Aux.No.

Operational StepPicture

No.Code Tools

1

Once rack of wire is all used up as shown, replace with new rack of wire by first removing the empty returnable wire rack from the horizontal decoiler using a forklift.

1 & 2 Forklift

2

Move returnable rack from the horizontal decoiler and set aside and out of the way on the ground. 3 & 4 Forklift truck

3

Grab returnable rack again with forklift, sticking the prongs underneath the wire retaining frame. Use ratchet to loosen the 4 screws that hold the retaining frame to the rack as shown in picture 6.

5 & 6 Forklift, ratchet

4

Pull wire retaining frame off the top of the rack and set on top of new coil rack as shown. Use ratchet, as shown in picture 6, to tighten the 4 screws of the frame to the rack.

7 & 8 Manual, ratchet

5

Lift rack of wire using forklift and move towards the horizontal decoiler.

9 Forklift truck

PhotosFeature

Data Retention Required Indicate By an 'R' Inside The Appropriate Symbol

Code Key

100% Inspection

1st / Every 25th / End Inspection

Custom Inspection

Safety

MF.30XXXX-1Work Instruction

This instruction applies to any GSI associate forming spring wire.

Issue DateAuthor

Small Spring Wire ProcessTitle

Purpose

To provide a step by step instruction on how to form spring wire from start to finish.

Scope

Revision DateTotal pages

Horizontal decoiler

Returnable rack

Wire retaining frame

Wire retaining frame

Rack of wire

Part #/ Process

QA Russ MeyerProduction

Nicki Ripperda

Reference Documents

1 2 3

4 5 6

7 8 9

7

Spaghetti Diagram

Spaghetti Diagram– Operator observation to determine common patterns of travel– Spaghetti Diagram on small parts packaging in finished goods

8

Control Plan

Develop Control Plan for production of galvanized fan process– Use previously made work instructions– Describe the actions required to assure that all phases of the process are in a state of control– Important tool for APQP (Advanced Product Quality Planning)

9

Capability Study

Hog Feeder Trough Capability Study– Measured five different critical measurements on 30 troughs of new hog feeder design– Entered data into Minitab program – From Minitab calculations, determined current process is not capable of repeatedly producing

parts within product specification– Determined how much the tolerance on the blueprint would need to change in order for the

process to become capable

22.222.122.021.921.821.7

LSL 21.767Target *USL 21.829Sample Mean 21.9542Sample N 30StDev(Overall) 0.110022StDev(Within) 0.110975

Process Data

Pp 0.09PPL 0.57PPU -0.38Ppk -0.38Cpm *

Cp 0.09CPL 0.56CPU -0.38Cpk -0.38

Potential (Within) Capability

Overall Capability

PPM < LSL 33333.33 44455.37 45842.80PPM > USL 833333.33 872366.50 870315.95PPM Total 866666.67 916821.86 916158.75

Observed Expected Overall Expected WithinPerformance

LSL USLOverallWithin

Process Capability Report for Overall WidthCurrent State Proposed State with tolerance change

Hog Feeder Trough