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. |
