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Design Approach Method
I 2.1 – Reduction in Vehicle Paint Rework
Victoria Arauz, Bryce Jimenez, Jose E Ramos, Isaac Salas
Ingram School of Engineering
Step 1. Identify the Problem
Step 3: Set a Target
Step 4: Cause Analysis
Step 7: Data Collection
Step 2: Break Down the Problem
Ultimate Goal: Reduce the rework cost associated with
an inadequate cleaning process of the assist jigs used to
hold open the tailgates and hoods of Toyota trucks in an
ergonomically safe manner.
Current Situation: In efforts to clean assist jigs, team
members are holding the jig on a vibrating surface and
slamming it against an anvil. The process is creating
quality defects as debris is transferred from the jigs to
the vehicle during the painting process.
Acknowledgements
Team Members
We would like to thank the following individuals for
their help on our project:
Mr. Julio Mata – Assistant Manager - Paint Engineering
Mr. Bill Harloe – Paint Quality Engineer
Mr. Roland Garcia – Maclellan Engineer
Toyota Kaizen Team
Dr. Patrick Thomas – Texas State University
Toyota’s 8 Step Process is used to break down, organize and
remove all waste in the process.
Step 6: See Counter Measures Through
1. Redesign the cleaning process to reduce the transfer
of debris which will reduce rework cost.
2. Improve the ergonomics of the cleaning operation.
3. Improve or maintain cycle times.
Brush Design
Exercise Jig DesignAir Pressure Design
Step 7: Data Analysis
1. Jig will be clamped into tray.
2. Tray will slide into chamber.
3. Blast with high air pressure
to remove zinc pellets.
4. Vacuum at the bottom to keep
area clean of zinc.
1. Clamp jig into tray.
2. Slide into chamber.
3. Vibrating gun on the side
will exercise jig coil to
remove zinc.
4. Vacuum at the bottom to
keep area clean of zinc.
1. Clamp jig on to
360 degree rotating
table.
2. Brush attached to drill
bit will then vibrate
between coil.
3. Debris collected by
trash bin.
Problem 2:
Assist Tailgate Jig
Assist Hood Jig
Current Problems:Problem 1:
Process is physically demanding
TM slams jig on anvil and
withstands vibration
To remove zinc pellets from jig
To clean jig
To avoid paint defects
Workers cycling out
quickly
Increase in number of defects near
hood and tailgate
Zinc pellets are falling on surface
Coil on jig contains left over
zinc
Zinc machine removes paint but
leaves debris
Insufficient process to clean jig
Increase in rework
cost
Step 5: Create Countermeasures
Step 8: Recommendations
CAD Simulation
Phase 1
Phase 2
First Design
Phase 1 Data:
Determined which combination of
cleaning mechanisms worked best.
Uncontrolled
variables:
1. Amount of zinc
in coil was
inconsistent and
varied per jig.
2. Deformed jig.
3. Zinc debris
collection.
Cycle Time:
Rework Savings:
Ergonomic Improvement:
Take away from Phase 1:
Evolution of Design
The Four Stages
• Improve ease of the jig's installation.
• Replicate the design to fit multiple jigs.
• Use Digital Twin to quantify ergonomic
improvements.
• Design enclosure around fixture.
• Funnel underneath enclosure to collect zinc debris.
• Evaluate Heijunka “Leveling”.
· Investment: $10,000
· Payback Period: 0.21 years
· Cost Reduction: $47,000
Insufficient or unnecessary
· ROI includes repair materials,
overtime for defects related to
improper cleaning, and
reduction in medical claim rate.
Optimal region