Title: Assignment4

Author: Shruthi Thota

Class: IE655
Date: 12-04-2016
eLearning Pack ID: IE655-Fall 2016-33-05
Collaborative Companies:
1. SAE INTERNATIONAL AUTOMOTIVE ENGINEERING
2. SAE INTERNATIONAL AEROSPACE & DEFENSE
TECHNOLOGY
3. FORCE BEYOND
4. INDO-MIM
Statement:
The assignment work was finished and submitted by Shruthi
Thota.
Content:
1. Introduction and Objectives of the Project
2. Brief Description of the methodologies applied
3. Main Body of the Project
4. Collaboration
5. Social Networking
6. Summary
7. Further Work Needed / Proposed
8. References
Introduction and Objectives:
The main purpose of the assignment is to develop, select or
identify Sustainable Green Design methodology and strategy for
Automotive Web Services. The focus of this experiment is to improve
the quality of our product. It will enhance on reducing the cost and time
required in each process by using various tools.

Brief Description of Methodologies Applied:

Various methods are used to improve the performance of our
company. We will use Value Stream Mapping (VSM) in order to
improve the time efficiency of our products. Along with this we will also
implement lean that aims on removing waste and Kaizen which focuses
on continuous improvement.
Main Body of the project:
Automotive Web Services has already implemented various
Concurrent engineering methods like CORA and PFRA in production of
various parts. These methods concentrate on identifying various errors
and problems in early stage and necessary precautions to be taken based
on these problems in advance to avoid wastage. To improve the quality
of our products we will be using various lean tools. Our company always
focuses on eliminating waste and implementing various green methods.
We will use KAIZEN to improve our performance. Kaizen is
defined as a process of continuous improvement; it was developed and
implemented by Japanese in several industries after Second World War.
It mainly focuses on eliminating waste products.

Since it focuses on continuous improvement, it contains some simple

steps to solve problems that occur on daily basis. The cycle of kaizen
activity is defined as:

Standardize an operation and activities,

Measure the operation (find cycle time and amount of inprocess inventory).

Gauge measurements against requirements.

Innovate to meet requirements and increase productivity.

Standardize the new, improved operations.

Continue cycle ad infinitum.

This can be done in 4 simple steps as follows:

Plan

Do

Check

Act or action

In this first you plan your process. Then Implement it. Then check for
errors or problems. Take action on the problems or errors if any. We can
implement it on each and every process.

According to the Japanese there are mainly 3 types of wastes:

Muda

Mura

Muri

We will also use SWOT Analysis to improve our business. In

SWOT Analysis we will evaluate Strengths, Weaknesses, Opportunities
and Threats. Strengths are defined as the best characteristics of our
company. Weaknesses if any are known in advance will be taken care in
time by implementing some tools like brainstorming etc. Everyone will
get various opportunities from time to time but doesnt get lot of benefits
from it because mostly we will fail to identify our opportunities so we
couldnt grab them in time. Seeking new opportunities and making full
use of them to start new ventures is always our look out. Threats are
defined as the factors which might slow down our business. These are
generally not in our hands and occur due to increased competition,
environmental changes and some other reasons. If we able to know them
in advance, we can tackle them with our full strengths.

Automotive Web Services plans to run a SWOT analysis for every

product and process that are developed in our company. This will help us
to increase our output.

We will use various softwares to develop our products like Catia,

Solid Works, Pro-E, etc. These software`s are very useful in designing,
developing parts and assemblies. Apart from this we will also use
ARENA to carry out value stream mapping for various processes. Arena
is discrete event simulation software that helps in finding out areas
where process time and cost can be reduced which is very helpful in
creating the basic flow charts of any processes. We can specify the
necessary details in this software like number of labors used, cost
required for each labor, types of machines used and their running cost,
etc. It gives an estimate of where we are wasting time by identifying
extra steps that are taken during any process. We will also collaborate
with other companies after running arena so that we can easily find out
where and when do we need to collaborate with other companies to
increase our production with help of this software.

This is a sample of VSM which we are using in our company. It covers

all the entities required during the process. The video below shows the
flow of a simple process.

Questions from Chapter 3

Q.1 Explain the Deming's 14 Rules of Management and Quality
Concepts and how Deming's 14 Rules affect our concurrent engineering
mission?
The Deming's 14 rules are as follows:
1. Managers should create consistency and continuity of purpose for the
improvement of products and services.
2. Leaders should refuse to allow commonly accepted levels of mistakes,
defects.
3. Building quality into the first phase to eliminate the need for and
dependence upon inspection.
4. Team should reduce the number of suppliers and do the business

based on statistical evidence, not on price.

5. Team must continually search problems in the system and find ways
to improve it in order to decrease the cost.
6. Organization has to set up modern methods of training and education
on the job for creating good products.
7. Organization needs to focus on leadership and supervision to help
workers do a better job.
8. Organization encourages open, honest, constructive communication
and eliminates fear in the company.
9. Organization has to break down barriers between departments.
10. Team should eliminate the use of numerical goals, slogans and
posters for the workers
11. Team use statistical methods to improve quality and eliminate
standards prescribing numerical quotas.
12. Let workers talk freely and discuss issues as they occur.
13. Organization institutes a program of regular education to keep
workers following new developments.
14. Leaders clearly define managements permanent commitment to
quality and productivity and assure the transformation is everybodys
job.
These are the simple rules designed by Dr. William Edwards Deming.
These rules will help our company to increase it production and avoid a
lot of defects at all levels of management.
Q.2 What are the advantages of design for quality, manufacturing and
assembly?
Due to increasing competition in the market, quality assurance has
become a necessity. In order to achieve this a perfect design in advance
should be designed by engineers. This design should contain the details
of manufacturing and assembly of the product. It helps in eliminating
defects in advance.
Q.3 What are the advantages of using minimum parts in a design?

Advantages of having minimum parts in a design are:

Minimum number of parts in an assembly makes it simple.

It is easy to carry out maintenance on assemblies with fewer
parts.

The cost of assembly decreases.

Cost of testing and processes required to carry out quality

assurance reduces.

Manufacturing processes become easy.

Q.4 What is Poka-Yoke?
POKA-YOKE is a Japanese term which means mistake-proofing. It
mainly involves the elimination of human error and aiming for zero
defects at all levels of work. Its purpose is to eliminate product defects
by preventing, correcting, or drawing attention to human errors as they
occur. In other words, designs and work practices should be such that
error is eliminated. This concept assumes people inherently make
mistakes but by creating designs, technology, systems, and procedures
that focus on the elimination of these errors, an error free organization
can be achievable.
Q.5 How does Kaizen help an organization?
KAIZEN is a Japanese term which means gradual product design and
process improvement over time. It is gradual improvement by breaking
through the current ways but still maintaining current improvements as
gradual improvements are applied. The aspects include the acceptance
that problems exist, acting as a team, and identification of problems.
Q.6 What is the importance of Design for De manufacturing,
disassembly and virtual product disassembly?

De manufacturing involves the disassembly and recycling of obsolete

consumer products. When a product reaches the end of its life it can be
broken down and reused or disposed of. The idea of design for de
manufacturing is that you take into account during the design phase, the
product may need to be broken down into reusable components or to be
disposed of. There are also products that may require de manufacturing
because it cannot be disposed of without separating toxic components.
Products like cars may need to be disassembled frequently for
maintenance. Tools such as virtual product disassembly can be in the
form of software tools which can assist with the breakdown of parts for
visualization without going through the physical process. The
disassembly can be modeled using this tool for various purposes.
Q.7 What is Quality circle?
A quality circle is a group of workers who do the same or similar work,
who meet regularly to identify, analyze and solve work-related
problems. Typical topics for the attention of quality circles are
improving occupational safety and health, improving product design,
and improvement in the workplace and manufacturing processes.
Q.8 What is MUDA, MURA and Muri?
Muda means waste. It includes all those factors which do not contribute
in the process and decrease the quality of project or increase the cost and
time of the project.
Mura means unevenness; irregularity; lack of uniformity; nonuniformity; inequality. It occurs due to lack of inventory or man power
at any point during the process. It increases the process time and reduces
profits.
Muri means unreasonableness; impossible; beyond one's power; too
difficult; by force; perforce; forcibly; compulsorily; excessiveness;
immoderation. It can be eliminated by planning the way in a standard

way. Standardization is nothing but making things easy for everyone to

carry out.
Q.9 What are the steps of Kanri?
KANRI is a Japanese term which means quality control is the
responsibility of the entire company from top level management to the
factory floor to develop, design, manufacture, inspect, market and
service products to the satisfaction of customers at the time of purchase
and beyond. Further more, it means the continual check on processes to
ensure they are meeting standards and well tested procedures. The four
steps include:
Plan Setting the criteria for controls and objectives
Do Perform operations per procedures and standards.
Check verify and study the results of the operation
Action Take actions based on the result.

Q.10 What are CNC machines?

Computer Numerical Control machine is the automation of machine
tools that are operated by precisely programmed commands encoded on
storage medium, as opposed to controlled manually via hand wheels or
levers, or mechanically automated via cams alone, operated through a
computer. These machines are highly accurate. They are really useful for
mass production. The initial cost of this machine is high. Due to high
production rate the initial cost can be recovered really fast and makes it
worth every penny.
Collaboration:

1.
2.
3.
4.

We will work with our 4 companies

SAE INTERNATIONAL AUTOMOTIVE ENGINEERING
SAE INTERNATIONAL AEROSPACE & DEFENSE
TECHNOLOGY
FORCE BEYOND
INDO-MIM

With help of VSM we will get an idea of which processes will be

increasing our process time. There will be some processes which will
be impossible for us to carry out due to lack of necessary machinery
and equipments. We will be off-loading or sub-contracting these
parts to our collaborating companies to increase our production.
Social Networking Content:

Samsung To Invest $1B In Texas Semiconductor

Production

Samsung Austin Semiconductor LLC announced Tuesday that the

company plans on investing more than $1 billion in their Austin facility
in the first half of 2017, adding new jobs to the area. The company plans
to use most of its one billion dollar investment on an advanced smart
chip, called system-on-chip products. "This means we're going to be
procuring a lot more equipment, installing tools into our 'fab' and
amping up our wafer production". Currently, Samsung employs 3,000
people in Austin, and most employees work in its manufacturing facility,
known as the 'fab' or 'foundry.' Starting next year, the company will need
hundreds of new manufacturing technicians and engineers to run all the
new equipment. I think the investment is good as it will create new jobs
to people.

Study suggests we're not as terrible at flying drones as

you might think
Drones rightly attract a healthy amount of attention when they put
people in danger, whether that be by flying too close to commercial
airliners or stopping firefighting crews from tending to blazes. But new
research is adding some clarity to the reasons behind the rising number
of drone incidents, suggesting that more often than not, technical
glitches rather than piloting errors are to blame.
If you've ever tried your hand at piloting a drone, then you'll understand
that things don't always go to plan. A slip of the joystick here, an
overzealous acceleration there, things can come unstuck pretty quickly
and the learning curve can be unforgiving. The US government has
introduced a smartphone app, an awareness campaign and mandatory
registration for these reasons: to keep rookie pilots both aware of the
dangers and accountable for any missteps.

Ford Recalls Over 88K Vehicles Due To Stalling Problem

Ford is recalling more than 88,000 cars and SUVs in North America
because the engines can stall without warning due to a fuel pump
problem. Ford says the fuel pump control modules can fail, and the
engines may not start, or they could stall, leaving drivers without the
ability to restart them. The company says its not aware of any crashes or
injuries from the problem. Dealers will replace the control module at no
cost to owners. It also says that its working with parts makers to ship
new modules quickly. Its better to recall than to suffer dangers.
Summary:
In this assignment I learned about various management tools like
kaizen, lean, SWOT analysis, etc. These tools are very important for any
companys growth.

Further Work Needed / Proposed:

There are plenty of other methods to improve the
management and overall growth of any company. We will study them as
per requirement and try to implement as much as possible.
References:
http://en.wikipedia.org/wiki/Kaizen
http://en.wikipedia.org/wiki/Muda_(Japanese_term)
http://en.wikipedia.org/wiki/Mura_(Japanese_term)
http://en.wikipedia.org/wiki/Muri_(Japanese_term)
http://en.wikipedia.org/wiki/SWOT_analysis
https://www.arenasimulation.com/
IE-655 Concurrent Engineering eLearning pack by prof. Ranky