Monday, July 16th , 2018

Project Listing

This is a detailed list of Equinox Projects by category. After each one is a brief description of the situation and benefit to the Client. (Numerical benefits are shown in orange text.)

Category Description Results
Cost Reduction - Runtime Implementation of adjustable boring bars Reduced tooling time; Saved thousands of dollars per year on special boring tools
Data Flow - Bill of Material Bill of Material Accuracy and Correction for Assembly/Flow Line; Coordinated with Digital Documentation group Met deadline for review of 110 Subassembly BOM's; Monitored Design and Mfg. Eng'g fixes 
Data Flow - Capacity Planning Work Cell Capacity balancing by part family and routing changes Achieved 4 work cell balanced load
Data Flow - Capacity Planning Part family analysis; routing changes Achieved machining area balanced load
Data Flow - Part Commonality Part Commonality between Product Lines Data assembled for 3 product lines and over 10,000 different part numbers
Data Flow - Scheduling Scheduling Accuracy, Shop software and data entry improvements Computer Scheduling accuracy improved by 20%
Data Flow - Scheduling Scheduling Accuracy, Shop software and data entry improvements Overnight data entry lag time eliminated
Data Flow - Setup Reduction DNC-Direct Numerical Control introduced into machining job shop Saved 20 minutes per setup for each of the machines connected. Improved CNC program accuracy
Fixture Design for Assembly Assembly of medical implantable devices for welding with cooling coils to remove unwanted heat  Enabled TIG welding process of titanium parts in inert environment; Prevented heat damage to interior components.
Fixture Design for Assembly Part Holding for Furnace brazing Enabled small parts to be furnace brazed
Fixture Design for Assembly Semi-automated fixture for electrical switch assembly-torque wrench Enabled Client to meet tooling up deadline; improved process safety and reliability
Fixture Design for Assembly Semi-automated fixture for electrical slide switch assembly Enabled Client to meet tooling up deadline
Fixture Design for Assembly Semi-automated fixture for thumb wheel assembly and lubrication Enabled Client to meet tooling up deadline
Fixture Design for Assembly; Quality @ the Source Fixture to eliminate bearing pressed into housing damage Saved $1000 per month in material scrap; Enabled assembly flow line to remain on schedule 
Fixture Design for Part Production; Setup Reduction Three position fixturing for machining of complex castings Eliminated two complete setups, reduced runtime, improved quality; Yielded 60% setup and runtime savings per part. 
Fixture Design for Part Production; Setup Reduction Two position fixturing for machining of complex castings Eliminated one complete setup, reduced runtime, improved quality; Yielded 30% setup and runtime savings per part. 
Flow Manufacturing Assembly Flow Line Calculations for Takt Time, Cell quantity, Cycle Time, Labor needed New order of Assembly created; cell creation
Flow Manufacturing Cycle Time Reduction Contributed to team and Six Sigma Analysis
Lead-time Reduction Work Cell formation, Visual manufacturing,Setup Reduction implemented Lead-time reduction 69%; from material supplied to work cell to finished part (42 days down to 13 days)
Lead-time Reduction Work Cell formation, improved scheduling, quality @ the source implemented Lead-time reduction 85%; from material supplied to work cell to finished part (35 days down to 5 days)
Lead-time Reduction Setup Reduction plus formation of Work Cell Lead-time Reduction 67%; from material supplied to shop to finished assembly (42 days down to 14 days)
Manufacturing Engineering Support Support for ME dept.; ECO's, Supplier Issues, Flow Line Support Material flow improvement, found/purchased wheeled transport, assembly fixturing for capital
Plant Layout Advised on placement of work cells, production line and heat treat facility  Successful implementation
Plant Layout, Material Flow Advised on placement of work cells, work centers, tool crib, maintenance and raw material facility  Successful implementation - reduced raw material storage area by 55%; Created area for one more work cell.
Process Improvement - Runtime Implementation of Through the Tool Coolant systems for Vertical Machining Centers. Reduced runtime by as much as 60%; Reduced tool wear; improved machined surface finish.
Setup Reduction Implementation Multiple Spindle Drill Press Improvement - Creation of dedicated head setups. Improved head storage. Time decrease from 2-5 hours to forty minutes per setup. Reduced setup times by 60%
Setup Reduction Implementation Horizontal Milling Machine Machine Runtime raised from 80 to 96%; Setup time reduced to 4%
Setup Reduction Kaizen Training and Implementation Horizontal Milling Machine Cross-functional Team trained; videotaped setup, successfully produced and implemented solutions
Setup Reduction Training Multiple Spindle Drill Press Improvement Cross-functional Team trained; videotaped setup, successfully produced and implemented solutions; presentation to Management 
Shop Floor Communication Detail drawings for microwave guide assembly Decreased assembly confusion; reduced assembly time by 20%
Shop Floor Communication Creation of Process Drawings from process sheets; maximize processes instruction data; including Drawing, Process and CNC rev. numbers. Speeds/feeds/fixturing and cutting tool numbers for a high volume part production line with dedicated equipment Reduced setup times, increased production rates by 22%
Total Productive Maintenance (TPM) TPM Implementation - Training, set up of TPM database, monitor MTBF, MTTF, Implement Daily PM's at work cells, work centers, Guided transfer of paper data into database Maintenance department. saved 100's of hours per year due to more up time from PM's and less time writing reports, looking for data with inventory of spare parts.
Training - Performance Measurements  Work Cell Performance Measurements Successful Training
Training - Performance Measurements  Performance Measurements Successful Training
Training - Work Cell Creation  Work Cell Creation for Management Successful Training
Training - Work Cell Operation  Work Cell Operation for the Workforce Successful Training
Training - Lean Manufacturing The Lean Approach Successful Training
Training - Lean Manufacturing The Lean Approach Successful Training
Training - Process Mapping Process Mapping for Waste Removal Successful Training
Training - Setup Reduction Setup Reduction for Cross-functional Teams Successful Training
Training - Setup Reduction Setup Reduction for Cross-functional Teams Successful Training
Training - Teams Cross-functional Team training with Quality Tools for Problem Solving Successful Training
Training - Teams Cross-functional Team training with Quality Tools for Problem Solving Successful Training
Training - Teams Cross-functional Team training with Quality Tools for Problem Solving Successful Training
Training - Total Productive Maintenance(TPM) TPM Training Successful Training
Training - Total Productive Maintenance(TPM) TPM and the Work Cell Successful Training
Training - World Class Manufacturing WCM and the 20 Keys Successful Training
Visual Manufacturing Three VMC Cells - Color Coding - Visual tool boards, Standardize tools, hardware, storage. Decreased work force searching for items Reduced the amount of overtime by 16 hours per week
Work Cell Creation Five cells including machining, grinding, balancing created based on part families and processes required Reduced the amount of overtime by 40 hours per week
Work Cell Creation, Lead-time improvement Blanking Cell, 4 VMC Cells-parts leave completed and go directly to heat treating Reduced part arrival time to assembly by 8 days (24%)
Workplace Organization Horizontal Machining Center - Clean, Organize area, improve fixture storage, tools moved closer. Improved safety, decreased fixture storage area by 33%; helped setup times by 14%
Workplace Organization - New Facility Setup of new tool crib in new facility. Successfully led new staff to select machining, grinding tools, tool holders, storage cabinets; sharpening equipment. Set initial re-order points
Workplace Organization - New Facility Tooling/Fixturing Standardization Successfully led new staff to set up descriptive numbering system for each. Established fixturing philosophy for part workholding.