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Designing Products for Cellular
          Assembly

    ADVENT DESIGN CORPORATION
             Bristol, PA
Presentation Goals
Review use of Six Sigma design
methodology & DMADV

Review how design impacts
assembly

Review coordination of design
development and cellular
assembly

Transition to the Six Sigma
DMAIC cycle

Follow a new product through
the cellular design process
Cellular Manufacturing

Re-arranging production operations to improve
  flow and to reduce handling and cycle time

Group products into families
Establish the required cycle time
Review the production sequence
Design the cell layout
Adjust work to balance flow

   How is this done during the design process ?
The DMADV Cycle
      Six Sigma In Action

Define &              Analyze
Measure              • Concepts




  Verify              Design
•Breadboard          • DFMEA
 • Prototype       • Requirements
                  System Design
                  Tolerance Design
                  Parameter Design
Design for Six Sigma
             Use of DMADV

Define:     Project Plan & ID Risks
Measure:    Voice of the Customer, Customer
            Requirements, Critical to Quality
Analyze:    Concepts, Key Functions, Design
            reviews
Design:     High Level Elements, Design
            Requirements, FMEA, Design Reviews
Verify:     Drawings, BOM, PDCA, Bread board,
            Prototype, Implementation Plan
Critical to Quality (CTQs)
                           (CTQs)
Convert Customer Needs into the Language of the
                Design Team

CTQs that affect cell design…

  Out of package start up reliability must be
  100%

  Process fluid batches must satisfy all
  chemistry requirements

  No leaks in any fluid paths
Analyze: Design & Process Concepts


                                         REVISED BETA TECHNICAL CONCEPT

                    CONCEPT APPROACH




Generate concepts
                    The primary goals of the revised Beta design are to reduce unit cost and the size of the unit. This can be
                    approached following three general paths:

                        1.   Cost and size reduction of individual components without affecting the process:

                             •   Tank(s)
                             •   Valves
                             •   Pumps
                             •   Sensors
                             •   Controls package



Combine concepts        2.   Cost and size reduction of individual components with some select process changes:

                             •
                             •
                                 Saline tank overflow fill of brine tank
                                 Saline flow regulation by pump motor speed control
                             •   Catholyte re-circulation through a small, positive displacement pump

                        3.   Significant process changes that target eliminating components and reducing complexity:

                             •   Continuous process concepts that eliminate the saline tank.



Select concepts
                    Regardless of the path selected, new components, whether resourced or re-sized or newly selected due to a
                    process change, must be fully tested. The revised beta will require a new review by NSF and UL.




Evaluate concepts
Process Concepts Lead to Machine
            Design


                                                                                                                                                                                                              HYDROGEN
                                                                                                                                                                                                               EXHAUST




                                                                                                                                       CATHOLYTE
                                                                             OVERFLOW TROUGH                                             RECIRC
                                                                                                                                        CHAMBER

                                                 BRINE
                                                 TANK
                                                  (T1)                                                                                                                       STERILOX
                                                                                                                                                                                        pH CHAMBER
                                                                                                                                                     FR-4                     CELLS
                                                                                                                                                                                         AND PROBE

                                                                                                           AQUALOX
                                                                                                             TANK
                                                                                                              (T3)
                                                                    BRINE PUMP                                                                                         S
                                                                      (SPEED
                                                                   CONTROLLED)
                                                                        PP-1                                                                                          SV-3
                                                                                                                                                        CATHOLYTE
                                       FR-2                                                                                                            RECIRC. PUMP
                                       .01 GPM
                                                                                                                                                        DIAPHRAM
                                                                                                                                                           TYPE
                                                                                                                                                            P-2

                                                                                                                                                                               FR-3


                                                                                                 ?
                                       FR-1
                                       .44 GPM
                                                                                               IN-LINE
                                                             M                              CONDUCTIVITY
                                                                                               METER

                                                            MV-1                                                                                                                                CONTINUOUS PROCESS OUT

                                                                                                                        M MV-3   P-3
                                     PRECISION                                                                                                                                                       AQUALOX AUTO OUT
                                      PRESSURE
                                                                          WASTE /
                                                                                                                 AQUALOX
                                     REGULATOR                             DRAIN                                  PUMPS
                                                                           TANK                                   P-3, P-4,      P-4
                                                                                                                                                                                                 AQUALOX MANUAL OUT
                                                                            (T4)                                    P-5


                                                                                                                                 P-5

                                                                                                             M
                                S




                                                                                                                                                   WASTE / DRAIN
                                                                                                                                                    MANIFOLD
                                     SV-1                                                     M MV-4                                                                                                 WASTE / DRAIN OUT
                                                                                                            MV-2

                                                 S



                                                     SV-2
                                                                                                                                                                                               EMERGENCY OVERFLOW OUT
                                                                            WASTE / DRAIN
                                                                              JETPUMP
                                                                                 P-6
                                                                                                                                                                                                     POTABLE WATER IN




SUMMARY OF DIFFERENCES COMPARED TO ALPHA PLUMBING SCHEMATIC (DWG 77818000):

1. THE SALINE TANK AND SALINE PUMP HAVE BEEN ELIMINATED. IN THEIR PLACES ARE A PRESSURE
REGULATOR TO ENSURE CONSISTENT FLOW.

2. CLOSED LOOP CONTROL OF THE BRINE PUMP (USING FEEDBACK FROM AN IN-LINE CONDUCTIVITY
METER) MAY NOT BE REQUIRED IF THE PROCESS IS STABLE WITH OPEN LOOP CONTROL.

3. CATHOLYTE RECIRULATION DRIVEN BY A SMALL MAG DRIVE PUMP.
Design Requirements & DFMEA
                                              The Beginning of Cellular Development
                                                                                                                                                               DESIGN REQUIREM ENTS
            Product
                                                          Failure Effects
        Component or      Failure Mode                                                      Causes                  Controls
                                                     (Consequence of Failure)
         Process Step                                                                                                                       G eneral
       7784-0004 Left  Sharp Edges               Laceration hazard -to Advent Techs, Laser cut not         Deburring to be included in
       Side Plate                                Customer Service Techs, End users. deburred as parts of   manufacturing process.                 1. M echanical:
       7784-0008 Right                                                               manufacturing         Part will be inspected                        a) O utside dim ensions
       Side Plate                                                                    process               during first article                          b) Target weight (dry):
                                                                                                           inspection.
       7784-0005 Base     Right angle face not Assembly of side and top cover          Tolerance not       Geometric tolerance                           c) Fasteners and hardware
                          maintained at 90 deg pieces difficult and causes top to      specified and       specified on drawing.                         d) W herever practical, com ponent m ounting will be m odular
                                               buckle on assembly                      therefore not       EVS will construct fixture to
                                                                                       maintained in       maintain perpendicularity
                                                                                                                                                             O ptions will be investigated to sim plify connections to
                                                                                       manufacture         during manufacture.                               pum ps and valves in order to reduce com ponents and
                                                                                                           Perpendicularity will be                          fittings.
                                                                                                           inspected during first article
                                                                                                           inspection.
                                                                                                                                                         e) Pum p type to be self-prim ing.
       7784-0010 Top      Radius from pressing   Inability to use same parts
                                                                                                                                                         f) All outlet ports from the unit shall be ½ FN PT.
       Cover              of PEM stud prevents   (washers/spacers) on each stud in                                                                2. S afety:
                          stnd offs to seat      an assembly and between                                                                                 a) Identified hazards will be labeled and/or guarded.
                          consistently           assemblies.
                                                 User interface inoperable-keypad to
                                                                                                                                                         b) G uards that lim it access to identified hazardous
                                                 mylar face distances vary and may                                                                           com ponents will require tools to be rem oved or will be
                                                 be too far or too close to operate.                                                                         interlocked.
                          Cracked Welds          Customer/End user disapproval -
                                                 dissatisfaction.
                                                                                                                                                         c) C onstruction with respect to electrical safety:
                          Operator interface cut Inability to use same parts                               Manufacturing to support                               (1) U nit will be constructed to m inim ize risk of liquids
                          away bowed > 0.005" (washers/spacers) on each stud in                            piece so that bow is                                       com ing in contact with hazardous voltages (60
                                                 an assembly and between                                   minimized.
                                                 assemblies.                                               Amount of Bow will be                                      volts peak or 50 V D C ).
                                                 User interface inoperable-keypad to                       inspected upon first article                           (2) The electrical enclosure will be open ventilated. As
                                                 mylar face distances vary and may                         inspection.                                                a result, there are scenarios that could result in
                                                 be too far or too close to operate.
       All Outside Covers Scratches/Sanding- Customer/End user disapproval -                                                                                          water entering the enclosure. The fram e, panels,
                          swirl marks            dissatisfaction.                                                                                                     and enclosure openings will be designed to
                                                                                                                                                                      m inim ize this risk. P lum bing leaks and
                                                                                                                                                                      piping/fitting failures will be taken into account.
                                                                                                                                                  3. A m bient environm ental operating requirem ents (tem perature,
                                                                                                                                                     hum idity, etc.)
                                                                                                                                                  4. C odes / regulations:

Design Failure Modes & Effects Analysis                                                                                                                  a) C U L
                                                                                                                                                         b) N SF – unit will be designed following guidance of N SF
                                                                                                                                                             C riteria C -2 – 1983, S pecial Equipm ent and/or D evices.


• Failure modes
                                                                                                                                                  5. Installation and service:
                                                                                                                                                                  (1) Features to facilitate testing, packaging, transport,
                                                                                                                                                                      installation and service of the unit:
                                                                                                                                                                  (2) Target service require m ents

• Consequences of failures                                                                                                                                        (3) The C ontroller firm ware shall be able to deduce
                                                                                                                                                                      and provide indication of m ost likely fault using the
                                                                                                                                                                      U nit C ontroller to enter into a diagnostic and test
                                                                                                                                                                      m ode using a portable com puter and serial port

• Causes                                                                                                                                                              into the C ontroller. It shall also be possible to view
                                                                                                                                                                      a detailed log of the Unit processing state values
                                                                                                                                                                      at the last good operating state and at the point of

• Controls
                                                                                                                                                                      a U nit shutdown.
Design Reviews


Crossfunctional teams                         ADVENT                             QS-00-03-010
                                                                                 Page 1 of 1
                                                                                                 Rev. B
                                                                                              15-May-03
                                              DESIGN CORP.                       FCG/drh

                                             CONTROLLED RECORD WHEN COMPLETED


                                                     PROJECT MEETING FORM


Team discussions          Meeting Date:

                          Attendees:


                          Company Name:                                  Project Name:

                          Major Items Discussed




Customer
participation             Action Items                  Responsibility         Projected Completion Date




Engineers &               Schedule Impact:



assemblers                Budget Impact:



                                       ADVENT DESIGN CORP. CONFIDENTIAL- ALL RIGHTS RESERVED
Use of 3 D Modeling
                   Easy Visualization




For Assembly

For Maintenance
Access

For Interference
Design Development & Cellular Design
              in Parallel
                 An Iterative Process

               Define &                       Analyze
               Measure                       • Concepts

                                 Cell                     Cellular
                              Requirements                Concepts
                Verify                        Design
              •Breadboard
               • Prototype              • Requirements
          • Drawings & BOM                 • FMEA

    Cellular Assembly Verification            Cellular Flow,
                                             Sequence, Layout
Cellular Concepts
      Based on Design Concepts
Selection of Main Assemblies

Identification & Selection of Subassemblies
Using 3D Model

Modular Assembly Concepts

Identification of complex assemblies for
fixturing
Basic Design Assembly Concept

    Electrical                         Front Plate
    Assembly                           Assembly



Subassemblies      Tank & Frame        Subassemblies
                 Supports Assemblies


   Waste Tank
   & Jet Pump                          Top Cover
    Assembly                           Assembly
Sequence of Cellular Assembly Steps
                                                                                               Subassemblies & Main
       Assembly Sequencing
       Main Assembly
                                                                                               Assemblies Listed in
Step
 1
 2
 3
       Mount standoffs to plate and glue to inside mounting plate(77810004) to tank on side.
       Glue peristaltic pump plate to tank
       Glue PH probe plate to tank.
                                                                                               Proposed Assembly
                                                                                               Order
 4     Remove interior mounting plate
 5     Assemble motor to motor mounting plate( rotate head 90 deg)
 6     Assemble motor assy to mounting plate
 7     Assembly manual valves to tank
 8     Assemble motor mounting plate to tank with stainless hardware
 9     Assemble pump to frame
 10    Assemble casters to frame with stainless hardware (2 locking 2 fixed)
 11    Build waste manifold assembly (77810029)
 12    Assemble waste manifold assembly to tank
 13    Build Burkett 121/131 manifold.(77810032)
 14    Assemble 121/131 manifold to tank
 15    Build peristaltic pump assembly
 16    Assemble peristaltic pump to tank
 17    Build water in/Auqalox out valve assembly (77810031)
 18    Build water In valve assembly (77810033)




                                                                                               Includes Final Test &
 19    Build Water in assembly (77810034)
 20    Install 1/2" tubing
 21    Make peristaltic pump tubing connections
 22    Place tank onto frame
 23    Glue tank-to-frame blocks and align
 24    Install 1/2" tubing to catholyte chamber




                                                                                               Packaging
 25    Glue cell mount blocks and catholyte chamber
 26    Build cell pack assembly
 27    Mount cell pack to tank
 28    Mount two pumps and make connections
 29    Install T3 manual drain and bracket
 30    Build lower valve assembly (77810030)
 31    Install lower valve assembly
 32    Install electrical wiring
 33    Install Transformer plate
 34    Install Electrical plate and
 35    Install sensors and fix with tape
 36    Brine door assembly w/ hinges, lock and knob
 37    Install exhaust fans 1 in electrical box , 1 for exhaust
 38    Mount duct on skin for exit
 39    Install cabling for boards, sensors, valves




                                                                                               Preliminary Quality
 40    Pressure test unit and check for leaks
 41    Fix leaks if found ( plan to build test fixtures prior to assembly to tank)
 42    Adjust sensors as necessary
 43    Fill tank with Brine
 44    Test unit to finalized test plan
 45    Make adjustments/recheck parts/ retest if problems occur




                                                                                               Checks
 46    Drain unit
 47    Flush unit with water
 48    Add external skins/ and top cover
 49    Add 4' hose and nozzle
 50    Polish unit, towel dry if necessary
 51    Place labels in accordance with UL standards/ including serial #
 52    Package unit, complete ISO paperwork/checkoff sheets
 53    Ship unit to customer




                                                                                               Preliminary Cycle times
Cellular Assembly Flow Concepts
                             Main & Subassemblies

                                                                               Packaging/shipment




                                                                                   Leak testing /
                                                                                  Product testing
                                                                            (Test to Final Qualificaiton
                                                                                    Test Plan)




                                                                                   Electrical
                                                                             Main Product Assembly




                                                                                                                                                                            Make
                                                                                   Mechanical
                                                                                                                                                                         connections
                                                                              Main Product Assembly
                                                                            (See Assembly sequencing)




                                                                                                                                                                         Add Cabling
                                                                                                              Mount Tank to
                                           Subassemblies
                                                                                                                 Frame




                                                                                                                                                                         Add Sensors

                                                                                                              Tank Assembly                            Frame Assembly
                                               Water in
                 121&131                                                                    Waste Manifold
                                              Assembly
                  Manifold                                                                    Assembly
                                             (77810034)
                 Assembly                                                                    (77810029)
                                               3 parts                                                                                                                                 Add Electronics
                (77810032)
                  14 parts                                                                                                                             Assemble Pump
                                                                                                                  Name                                    to Frame
                   35 min                                                                                          Title                                     7 min




                                                                                                                                                                                                     Tank & Frame
                                                                                           Machine Mainfold
                             Water In/Aqualox              Water In Valve                     in house
                              out Assembly                   Assembly
                               (77810031)                   (77810033)
                                 7 parts                      9 parts                                                                                 Assemble casters
                                                                                                              Glue Mount top
                                                              13 min                                                                                      to frame
                                                                                                              securing blocks
                                                                                                                                                           10 min




                             Glue Couplings to
                              Manifold 24 hrs
                                  3 min
                                                                                                                                     Interior Plate
                                                                                                                                       Assembly                                                       Assemblies
                                                                                                                                   Assemble Pump
                                                                                                                                   to plate , rotate
                             Machine Manifold                                                                                       head of pump
                              (77810007) &                                                                                            add fitting
                                Machine                                                                                                 15 min
                                couplings




                                                                                                                                   Valves to Tank
                                                                                                                                       6 min


                                                                                                                                         Glue
                                                                                                                                1.Peristaltic plate 2.
                                                                                                                                PH mount
                                                                                                                                3. Catholite chamber
                                                                                                                                4. Cell Mounting
                                                                                                                                Block to Tank
                                                                                                                                 32 min




Subassemblies                                                                                                                     Assembly Blocks
                                                                                                                                  to plates & Glue
                                                                                                                                       to tank
Main Assembly & Subassemblies




• Cell Pack Subassembly
• Cell Pack Fits to Front Plate Assembly
• Front Plate Fits to Tank
Sub Assembly Flow
                                  Preliminary Cell Work Process Flow & Sequence
    Main Assembly Flow

       Mount components                                                                                    Shipping/Receiving
      to power supply plate                                                                              Inspection/Parts Supply
           Sub # 1A                                                                                                #9
                                       Base,Fans, Line cord
                                        Cell Power Supply
                                      Sterilox Tank Assembly
                                                                              Start traveler &
                                      Traveler checkbox # 1                 assign serial number                                          Test Unit
                                                                                                                                             #7



  Inlet/Outlet Plate
  Assembly & Test

Traveler checkbox # 2                             Assemble on Carts

                                                                                                                         Waste Tank/ Brine Tank
                                                                                             Plumbing                                                 Assemble Salt Chute
          Front Plate Assembly               Electrical Assembly                                                          / Jet Pump Assembly
                                                                                                                                                       Close up & Pack
                                                                                       Traveler checkbox # 4                                                 #8
          Traveler checkbox # 3             Traveler checkbox # 4                                                         Traveler checkbox # 5




                                       Assemble boards        Peristaltic
                                           to plate           Pump Assy


        Build subassemblies


                                                                                                                                      .
Assembly Drawings & BOM Based on
                 Cellular Flow




• Required parts
• Assembly notes
• Quality requirements & checks
Sub Assembly Flow
                                               Cellular Assembly Flow & Sequence Chart
          Main Assembly Flow
                                                                               Build Cell
                                                       Sterilox tank             Power
                                      Build Cell
                                                         & sensor               Supply
                                        Pack                                                                                                         Supervisor OK
                                                        7756-1107              7756-1112
                                      7756-1113                                                         Receiving                                    to ship Check
                                                                                                  Inspection/Parts Supply                             Sign traveler


Build Outlet           Build Inlet                   Base,Fans, Line Cord
 assembly               assembly                      Cell Power Supply
7756-1126              7756-1109                    Sterilox Tank Assembly                                                                 Quality Assurance
                                                                                                                                                                                 Package Unit
                                                      7756-1104 & 1128                      Start traveler &                               Checklist Review
                                                    Traveler initial box # 1             assign serial number                                                               Traveler initial box
                                                                                                                                              Sign traveler



        Inlet/Outlet Valve
         Assembly & Test                                                                                                               Burn-In & Test Unit
            7756-1125
      Traveler initial box # 2                                                                                                           Add test data to
                                                                                                                                            traveler




                                                                                                           Plumbing & Waste Tank                                 Assemble Salt Chute &
                 Front Plate Assembly                       Electrical Assembly                                   / Brine Tank                                        Top Cover
                      7756-1110                                 7756-1119                                    / Jet Pump Assembly                                  Close Up & UL Test
                 Traveler initial box # 3                  Traveler initial box # 4                                7756-1100                                          7756-1111
                                                                                                                                                                  Traveler initial box              Labeling
                                                                                                            Traveler initial box # 5
                                                                                                                                                                                                   7756-1102

                                                                                      Remote programming
                                                                                                                                               Tubing
Build pH Chamber                 Build Catholyte Chamber                                      port
                                                                                                                                              7756-1129
    7756-1115                           7756-1114                                         7756-1118
                                                                                                                                                                                           Cover assembly
                                                                                                                                                                  U/I assembly
                                                                                                                                                                                             7756-1102
                                                                                                                                                                   7756-1124
                                                                                Peristaltic
               Build conductivity probe               Assemble Boards                                    Jet Pump &               Brine Tank
                                                                                  Pump
                      7756-1116                        to Electric Plate                                 Waste Tank                assembly
                                                                                Assembly
                                                                                7756-1117                  assembly               7756-1106
                                                                                                          7756-1108
Guidelines for Lean Cell Design
Each operation is ergonomically designed

Machines are arranged in the sequence of
operations needed to process the part

All operations needed to make the part in the
cell and have process time < CT or Takt time

Work stations equipped with pokayokes
which perform as self inspections

Aisle width is 4 ft.
Preliminary Cell Layout




Follows Cell Flow and Sequence
   Implementation Planning
Questions to Ask About the Value
 Stream Represented by the Cell

Is the operation valuable?

Is the operation flexible?

Is the operation cycle time within takt time?

Are the operations balanced?
Verify Design & Cellular Concept




      Bread Board
• Verify design concepts
• Parameter Design of           Prototypes
  Experiments               Verify design & cell
Verify BOM & Material Staging for the
              Cell

                    Lead time

                    Space Availability

                    Reduce cell
                    assembler material
                    handling

                    Level of Material
                    Control (kanban)
Verify Quality System


             Final Test

             Work Station Checks

             Vendor Process
             Capabilities

             Documentation

          Build Customer Confidence!
Establish Assembler Knowledge & Training
  Requirements based on Cellular Design
          ID       S uba sse mbly/Ope ra tion


            T a nk & Ba se Assy
          1 Cell Subassembly                      1                       X   T                       T
          2 Cell Power Supply                     1           T           X   T
          3 Base and Tanks                        1                   X       T                       T
            Inle t/Outle t a sse mbly
          4 Inlet/Outlet Mounting Plate           2                       -   X                       T
          5 Jet Pump Water in Assembly            2                       -   X                       T
          6 Process Water In Assembly             2                       -   X                       T
          7 Output Valve Assembly                 2                       X   X                       T
          8 Assemble/Test Inlet/Outlet Assembly   2                       X   X                       T

               Front P la te Assy
          9    Catholyte Chamber Assembly         3           X           X   X   X           T
          10   pH Probe Assembly                  3           X           X   X   X           T
          11   Conductivity Probe Assembly        3           X           X   X   X           T
          12   Assemble/Test Front Plate          3           X           X   X   X           T
               E le ctrica l Assy
          11   Remote Program Port Assembly       4   T       T       X               X   X
          12   Electrical Plate Assembly          4           T       X           X   X   X   X
          13   Signal Transformer Assembly        4           T                       X   X       T
          14   Peristaltic Pump Assembly          4           T                       X   X
          15   Sensor Calibration                 4           T                       X   X       X
          16   Cuno Jack Wiring/Soldering                     T                       X   X       T
               Electrical Component
          17                                      4           T                       X   X
               Wiring/Mounting
               P lumbing/ T ubing
          18   Side Tubing Connections            5                               X               T
               Tubing Interconnection-Aqualox
          18                                      5                               X               T
               Tank
          18 Waste Chamber & Front Plate Tubing 5                                 X               T
          19   Assemble Tank & Pump to unit       5                               X               T
          20   Jet Pump Assembly                  6                               X           X
          21   Waste Chamber Assembly             6           X                   X           T
          22   Brine Tank Assembly                6                               X           X   T
          23   T e st                             7   T   T                           X   X
          24   S a lt D oor                       8               T               X   X
          25   Ope ra tor Inte rfa ce / Cove rs   8               T
          26   Ground P lug Asse mbly             8               T               X
          27   Fina l U nit Che ck                8           T   T                   X   X
          28   Packing                            9           T   T   X                       T

               T - Trainer for task
               X - Trained to perform task
Pre-Production Cellular Assembly Flow, Sequence & Quality Chart
          Sub Assembly Flow


           Main Assembly Flow
                                                                                 Build Cell
                                                         Sterilox tank             Power
                                       Build Cell
                                                           & sensor               Supply
                                         Pack                                                                                                          Supervisor OK
                                                          7756-1107              7756-1112                                  Workstation
                                       7756-1113                                                          Receiving                                    to ship Check
                                                                                                                           Quality Check
                                                                                                    Inspection/Parts Supply                             Sign traveler
                                                                                                                             incoming
                                                                                                                                                                                           Workstation
                                                                                                                              receipts
                                                                                                                                                                                          Quality Check
 Build Outlet            Build Inlet                   Base,Fans, Line Cord
  assembly                assembly                      Cell Power Supply
 7756-1126               7756-1109                    Sterilox Tank Assembly                                                                 Quality Assurance
                                                                                                                                                                                        Package Unit
                                                        7756-1104 & 1128                      Start traveler &                               Checklist Review
                                                      Traveler initial box # 1             assign serial number                                                                      Traveler initial box
                                                                                                                                                Sign traveler
                                                                                                CM-19-03-
                                                                                                010 Rev A
                                                                  Workstation
          Inlet/Outlet Valve                                       Quality
           Assembly & Test           Workstation                    Check
                                                                                                                                         Burn-In & Test Unit
              7756-1125             Quality Check                                                                                                                        Label Check
        Traveler initial box # 2                                                                                                           Add test data to         Final calibration & test
                                                                                                                                              traveler
                                                                                                                                                                    CM-19-01-002 Rev A




                                                                                                             Plumbing & Waste Tank                                     Assemble Salt Chute &
                  Front Plate Assembly                        Electrical Assembly                                   / Brine Tank                                            Top Cover
 Workstation           7756-1110                                  7756-1119                                                                                             Close Up & UL Test
                                                                                                               / Jet Pump Assembly
Quality Check     Traveler initial box # 3                   Traveler initial box # 4                                                                                       7756-1111
                                                                                                                     7756-1100
                                                                                                                                                                        Traveler initial box                 Labeling
                                                                                                              Traveler initial box # 5
                                                                                                                                                                                                            7756-1102
                                                                                                                                                                            Assembly &
                                                                                        Remote programming         Workstation
                                                                  Workstation                                                                    Tubing                   Quality Checklist
                                                                                                port              Quality Check
 Build pH Chamber                  Build Catholyte Chamber         Quality                                                                      7756-1129
                                                                                            7756-1118                                                                      CM-19-03-012
     7756-1115                            7756-1114                 Check
                                                                                                                                                                                                   Cover assembly
                                                                                                                                                                         U/I assembly
                                                                                                                                                                                                     7756-1102
                                                                                                                                                                          7756-1124
                                                                                  Peristaltic
                Build conductivity probe                Assemble Boards                                     Jet Pump &              Brine Tank
                                                                                    Pump
                       7756-1116                         to Electric Plate                                  Waste Tank               assembly
                                                                                  Assembly
                                                                                  7756-1117                   assembly              7756-1106
                                                                                                             7756-1108                                        Note: Green accepted labels will be applied to
                                                                                                                                                              subassemblies at specified workstations when
                                                                                                                                                              they pass the go/no-go test and inspection.
Transition from DMADV to DMAIC
                                Pre-Production Build & Evaluation
Fitting Leak                   59                                                             1st 100 Build
Assembly Defect
pH Control Failure
Conductivity Control Failure
                               37
                               33
                               18
                                                          70
                                                                                     Overall Defect Pareto Analysis
                                                                                                                                                                                          FMEA using Final Test
                                                                                                                                                                                          Data
Tank Leak                      11                               59
                                                          60
                                       # of Occurrences




SV-7 no/too little flow         7
                                                          50
                                                                                        37
                                                          40                                                  33
                                                          30
                                                                                                                                        18
                                                          20                                                                                                 11
                                                                                                                                                                               7
Conductivity Probe             10                         10
pH Probe
CPU
                                1
                                5
                                                           0
                                                                                                                                                                                          Service History
                                                                 Fitting Leak



                                                                                      Assembly




                                                                                                           pH Control



                                                                                                                                 Conductivity




                                                                                                                                                            Tank Leak



                                                                                                                                                                           SV-7 no/too
                                                                                       Defect




                                                                                                                                                                            little flow
                                                                                                            Failure



                                                                                                                                   Control
                                                                                                                                   Failure
Inoperable                     20




Incorrect assembly
Sensor not secure
Loose Connections
                                13
                                 7
                                 5
                                                                                             1st 100 Build
                                                                                    Assembly Defect Pareto Analysis                                                                       Compare data to
                                                                                                                                                                                          determine product &
Damaged/malfunctioned component 5
Sensor incorrect location        3                        14   13
                                     # of Occurrences




Other                            3                        12
                                                          10


                                                                                                                                                                                          cell design changes(can
                                                           8                               7
                                                           6                                                      5                      5
                                                           4                                                                                                  3                3
                                                           2
                                                           0
                                                                                                                                                                                          establish ratios)
                                                               Incorrect assembly




                                                                                                             Loose Connections




                                                                                                                                                        Sensor incorrect
                                                                                       Sensor not secure




                                                                                                                                  Damaged/malfunction




                                                                                                                                                                             Other
                                                                                                                                     ed component




                                                                                                                                                           location




                                                                                                                                                                                          Customer feedback
Pre-Production Cell Design & Flow to
      Eliminate the Eight Wastes

Inventory (more than one piece flow)
Overproduction (more or sooner than needed)
Correction (inspection and rework)
Material Movement
Waiting
Motion
Non-Value Added Processing
Underutilized People
Changes to Cell Design from Quality &
             Service Data
          Reduce Defects & Cycle Time


Change design & method of connecting piping
fittings & pressure testing to eliminate leaks &
reduce cycle time

Simplified final test procedure through improved
conductivity control

Simplified waste tank assembly

Vendor to supply wire harnesses
Product & Cellular Design Continue
                 in Parallel

 DMAIC                 Define &                       Analyze
  Cycle                Measure                       • Concepts

                                         Cell                     Cellular
Pre-Production                        Requirements                Concepts
     Cell
                        Verify                        Design
                      •Breadboard
                       • Prototype              • Requirements
                  • Drawings & BOM                 • FMEA

            Cellular Assembly Verification            Cellular Flow,
                                                     Sequence, Layout
After DMADV: the DMAIC Cycle
            Six Sigma In Action


               SDCA     Measure &           Plan-Do-Study-Act
   Define
                         Analyze            Teams
                                            Benchmark
                                            Analysis tools
SDCA                                        ID variability

                                          Employee Involvement

                          Improve            Design of
  Control
                      Plan-Do-Study-Act     Experiments


       SDCA = Standardize-Do-Check-Adjust
Lessons Learned
Specify everything:
fasteners, tube lengths,
etc. (or the assemblers will
guess)
Avoid tight fits. Watch
stack up tolerances
Understand vendor
capabilities
Have vendors supply
complete subassemblies
Need to verify BOMs at
each workstation
Have assemblers
participate in prototype
assembly
Designing Products for Lean Cellular Assembly

 Methodology that maximizes value and
 achieves improvement in…..
 Customer satisfaction

       Operating costs

   Process speed(lead time)

        Inventory & invested capital

           Quality

             Operating flexibility
Contact Information

       Advent Design Corporation
      Canal Street and Jefferson Ave.
            Bristol, PA 19007

          www.adventdesign.com
             800-959-0310

Frank Garcia, Director Engineering Services
     frank.garcia@adventdesign.com

       Thomas A. Lawton, President
      Tom.lawton@adventdesign.com
Bill Chesterson   CEO
                                         Automation & Product Design
 Advent Design                           215 781 0500 Ext: 203
  Corporation                            bill.chesterson@adventdesign.com

   925 Canal Street       Tom Lawton     President
   Bristol PA, 19007                     Contract Manufacturing
                                         215 781 0500 Ext: 202
   (P) 215 781 0500
   (F) 215 781 0508                      tom.lawton@adventdesign.com

www.adventdesign.com     Frank Garcia    Director
                                         Planning & Productivity
                                         215 781 0500 Ext: 207
                                         frank.garcia@adventdesign.com

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Designing Products for Cellular Assembly

  • 1. Designing Products for Cellular Assembly ADVENT DESIGN CORPORATION Bristol, PA
  • 2. Presentation Goals Review use of Six Sigma design methodology & DMADV Review how design impacts assembly Review coordination of design development and cellular assembly Transition to the Six Sigma DMAIC cycle Follow a new product through the cellular design process
  • 3. Cellular Manufacturing Re-arranging production operations to improve flow and to reduce handling and cycle time Group products into families Establish the required cycle time Review the production sequence Design the cell layout Adjust work to balance flow How is this done during the design process ?
  • 4. The DMADV Cycle Six Sigma In Action Define & Analyze Measure • Concepts Verify Design •Breadboard • DFMEA • Prototype • Requirements System Design Tolerance Design Parameter Design
  • 5. Design for Six Sigma Use of DMADV Define: Project Plan & ID Risks Measure: Voice of the Customer, Customer Requirements, Critical to Quality Analyze: Concepts, Key Functions, Design reviews Design: High Level Elements, Design Requirements, FMEA, Design Reviews Verify: Drawings, BOM, PDCA, Bread board, Prototype, Implementation Plan
  • 6. Critical to Quality (CTQs) (CTQs) Convert Customer Needs into the Language of the Design Team CTQs that affect cell design… Out of package start up reliability must be 100% Process fluid batches must satisfy all chemistry requirements No leaks in any fluid paths
  • 7. Analyze: Design & Process Concepts REVISED BETA TECHNICAL CONCEPT CONCEPT APPROACH Generate concepts The primary goals of the revised Beta design are to reduce unit cost and the size of the unit. This can be approached following three general paths: 1. Cost and size reduction of individual components without affecting the process: • Tank(s) • Valves • Pumps • Sensors • Controls package Combine concepts 2. Cost and size reduction of individual components with some select process changes: • • Saline tank overflow fill of brine tank Saline flow regulation by pump motor speed control • Catholyte re-circulation through a small, positive displacement pump 3. Significant process changes that target eliminating components and reducing complexity: • Continuous process concepts that eliminate the saline tank. Select concepts Regardless of the path selected, new components, whether resourced or re-sized or newly selected due to a process change, must be fully tested. The revised beta will require a new review by NSF and UL. Evaluate concepts
  • 8. Process Concepts Lead to Machine Design HYDROGEN EXHAUST CATHOLYTE OVERFLOW TROUGH RECIRC CHAMBER BRINE TANK (T1) STERILOX pH CHAMBER FR-4 CELLS AND PROBE AQUALOX TANK (T3) BRINE PUMP S (SPEED CONTROLLED) PP-1 SV-3 CATHOLYTE FR-2 RECIRC. PUMP .01 GPM DIAPHRAM TYPE P-2 FR-3 ? FR-1 .44 GPM IN-LINE M CONDUCTIVITY METER MV-1 CONTINUOUS PROCESS OUT M MV-3 P-3 PRECISION AQUALOX AUTO OUT PRESSURE WASTE / AQUALOX REGULATOR DRAIN PUMPS TANK P-3, P-4, P-4 AQUALOX MANUAL OUT (T4) P-5 P-5 M S WASTE / DRAIN MANIFOLD SV-1 M MV-4 WASTE / DRAIN OUT MV-2 S SV-2 EMERGENCY OVERFLOW OUT WASTE / DRAIN JETPUMP P-6 POTABLE WATER IN SUMMARY OF DIFFERENCES COMPARED TO ALPHA PLUMBING SCHEMATIC (DWG 77818000): 1. THE SALINE TANK AND SALINE PUMP HAVE BEEN ELIMINATED. IN THEIR PLACES ARE A PRESSURE REGULATOR TO ENSURE CONSISTENT FLOW. 2. CLOSED LOOP CONTROL OF THE BRINE PUMP (USING FEEDBACK FROM AN IN-LINE CONDUCTIVITY METER) MAY NOT BE REQUIRED IF THE PROCESS IS STABLE WITH OPEN LOOP CONTROL. 3. CATHOLYTE RECIRULATION DRIVEN BY A SMALL MAG DRIVE PUMP.
  • 9. Design Requirements & DFMEA The Beginning of Cellular Development DESIGN REQUIREM ENTS Product Failure Effects Component or Failure Mode Causes Controls (Consequence of Failure) Process Step G eneral 7784-0004 Left Sharp Edges Laceration hazard -to Advent Techs, Laser cut not Deburring to be included in Side Plate Customer Service Techs, End users. deburred as parts of manufacturing process. 1. M echanical: 7784-0008 Right manufacturing Part will be inspected a) O utside dim ensions Side Plate process during first article b) Target weight (dry): inspection. 7784-0005 Base Right angle face not Assembly of side and top cover Tolerance not Geometric tolerance c) Fasteners and hardware maintained at 90 deg pieces difficult and causes top to specified and specified on drawing. d) W herever practical, com ponent m ounting will be m odular buckle on assembly therefore not EVS will construct fixture to maintained in maintain perpendicularity O ptions will be investigated to sim plify connections to manufacture during manufacture. pum ps and valves in order to reduce com ponents and Perpendicularity will be fittings. inspected during first article inspection. e) Pum p type to be self-prim ing. 7784-0010 Top Radius from pressing Inability to use same parts f) All outlet ports from the unit shall be ½ FN PT. Cover of PEM stud prevents (washers/spacers) on each stud in 2. S afety: stnd offs to seat an assembly and between a) Identified hazards will be labeled and/or guarded. consistently assemblies. User interface inoperable-keypad to b) G uards that lim it access to identified hazardous mylar face distances vary and may com ponents will require tools to be rem oved or will be be too far or too close to operate. interlocked. Cracked Welds Customer/End user disapproval - dissatisfaction. c) C onstruction with respect to electrical safety: Operator interface cut Inability to use same parts Manufacturing to support (1) U nit will be constructed to m inim ize risk of liquids away bowed > 0.005" (washers/spacers) on each stud in piece so that bow is com ing in contact with hazardous voltages (60 an assembly and between minimized. assemblies. Amount of Bow will be volts peak or 50 V D C ). User interface inoperable-keypad to inspected upon first article (2) The electrical enclosure will be open ventilated. As mylar face distances vary and may inspection. a result, there are scenarios that could result in be too far or too close to operate. All Outside Covers Scratches/Sanding- Customer/End user disapproval - water entering the enclosure. The fram e, panels, swirl marks dissatisfaction. and enclosure openings will be designed to m inim ize this risk. P lum bing leaks and piping/fitting failures will be taken into account. 3. A m bient environm ental operating requirem ents (tem perature, hum idity, etc.) 4. C odes / regulations: Design Failure Modes & Effects Analysis a) C U L b) N SF – unit will be designed following guidance of N SF C riteria C -2 – 1983, S pecial Equipm ent and/or D evices. • Failure modes 5. Installation and service: (1) Features to facilitate testing, packaging, transport, installation and service of the unit: (2) Target service require m ents • Consequences of failures (3) The C ontroller firm ware shall be able to deduce and provide indication of m ost likely fault using the U nit C ontroller to enter into a diagnostic and test m ode using a portable com puter and serial port • Causes into the C ontroller. It shall also be possible to view a detailed log of the Unit processing state values at the last good operating state and at the point of • Controls a U nit shutdown.
  • 10. Design Reviews Crossfunctional teams ADVENT QS-00-03-010 Page 1 of 1 Rev. B 15-May-03 DESIGN CORP. FCG/drh CONTROLLED RECORD WHEN COMPLETED PROJECT MEETING FORM Team discussions Meeting Date: Attendees: Company Name: Project Name: Major Items Discussed Customer participation Action Items Responsibility Projected Completion Date Engineers & Schedule Impact: assemblers Budget Impact: ADVENT DESIGN CORP. CONFIDENTIAL- ALL RIGHTS RESERVED
  • 11. Use of 3 D Modeling Easy Visualization For Assembly For Maintenance Access For Interference
  • 12. Design Development & Cellular Design in Parallel An Iterative Process Define & Analyze Measure • Concepts Cell Cellular Requirements Concepts Verify Design •Breadboard • Prototype • Requirements • Drawings & BOM • FMEA Cellular Assembly Verification Cellular Flow, Sequence, Layout
  • 13. Cellular Concepts Based on Design Concepts Selection of Main Assemblies Identification & Selection of Subassemblies Using 3D Model Modular Assembly Concepts Identification of complex assemblies for fixturing
  • 14. Basic Design Assembly Concept Electrical Front Plate Assembly Assembly Subassemblies Tank & Frame Subassemblies Supports Assemblies Waste Tank & Jet Pump Top Cover Assembly Assembly
  • 15. Sequence of Cellular Assembly Steps Subassemblies & Main Assembly Sequencing Main Assembly Assemblies Listed in Step 1 2 3 Mount standoffs to plate and glue to inside mounting plate(77810004) to tank on side. Glue peristaltic pump plate to tank Glue PH probe plate to tank. Proposed Assembly Order 4 Remove interior mounting plate 5 Assemble motor to motor mounting plate( rotate head 90 deg) 6 Assemble motor assy to mounting plate 7 Assembly manual valves to tank 8 Assemble motor mounting plate to tank with stainless hardware 9 Assemble pump to frame 10 Assemble casters to frame with stainless hardware (2 locking 2 fixed) 11 Build waste manifold assembly (77810029) 12 Assemble waste manifold assembly to tank 13 Build Burkett 121/131 manifold.(77810032) 14 Assemble 121/131 manifold to tank 15 Build peristaltic pump assembly 16 Assemble peristaltic pump to tank 17 Build water in/Auqalox out valve assembly (77810031) 18 Build water In valve assembly (77810033) Includes Final Test & 19 Build Water in assembly (77810034) 20 Install 1/2" tubing 21 Make peristaltic pump tubing connections 22 Place tank onto frame 23 Glue tank-to-frame blocks and align 24 Install 1/2" tubing to catholyte chamber Packaging 25 Glue cell mount blocks and catholyte chamber 26 Build cell pack assembly 27 Mount cell pack to tank 28 Mount two pumps and make connections 29 Install T3 manual drain and bracket 30 Build lower valve assembly (77810030) 31 Install lower valve assembly 32 Install electrical wiring 33 Install Transformer plate 34 Install Electrical plate and 35 Install sensors and fix with tape 36 Brine door assembly w/ hinges, lock and knob 37 Install exhaust fans 1 in electrical box , 1 for exhaust 38 Mount duct on skin for exit 39 Install cabling for boards, sensors, valves Preliminary Quality 40 Pressure test unit and check for leaks 41 Fix leaks if found ( plan to build test fixtures prior to assembly to tank) 42 Adjust sensors as necessary 43 Fill tank with Brine 44 Test unit to finalized test plan 45 Make adjustments/recheck parts/ retest if problems occur Checks 46 Drain unit 47 Flush unit with water 48 Add external skins/ and top cover 49 Add 4' hose and nozzle 50 Polish unit, towel dry if necessary 51 Place labels in accordance with UL standards/ including serial # 52 Package unit, complete ISO paperwork/checkoff sheets 53 Ship unit to customer Preliminary Cycle times
  • 16. Cellular Assembly Flow Concepts Main & Subassemblies Packaging/shipment Leak testing / Product testing (Test to Final Qualificaiton Test Plan) Electrical Main Product Assembly Make Mechanical connections Main Product Assembly (See Assembly sequencing) Add Cabling Mount Tank to Subassemblies Frame Add Sensors Tank Assembly Frame Assembly Water in 121&131 Waste Manifold Assembly Manifold Assembly (77810034) Assembly (77810029) 3 parts Add Electronics (77810032) 14 parts Assemble Pump Name to Frame 35 min Title 7 min Tank & Frame Machine Mainfold Water In/Aqualox Water In Valve in house out Assembly Assembly (77810031) (77810033) 7 parts 9 parts Assemble casters Glue Mount top 13 min to frame securing blocks 10 min Glue Couplings to Manifold 24 hrs 3 min Interior Plate Assembly Assemblies Assemble Pump to plate , rotate Machine Manifold head of pump (77810007) & add fitting Machine 15 min couplings Valves to Tank 6 min Glue 1.Peristaltic plate 2. PH mount 3. Catholite chamber 4. Cell Mounting Block to Tank 32 min Subassemblies Assembly Blocks to plates & Glue to tank
  • 17. Main Assembly & Subassemblies • Cell Pack Subassembly • Cell Pack Fits to Front Plate Assembly • Front Plate Fits to Tank
  • 18. Sub Assembly Flow Preliminary Cell Work Process Flow & Sequence Main Assembly Flow Mount components Shipping/Receiving to power supply plate Inspection/Parts Supply Sub # 1A #9 Base,Fans, Line cord Cell Power Supply Sterilox Tank Assembly Start traveler & Traveler checkbox # 1 assign serial number Test Unit #7 Inlet/Outlet Plate Assembly & Test Traveler checkbox # 2 Assemble on Carts Waste Tank/ Brine Tank Plumbing Assemble Salt Chute Front Plate Assembly Electrical Assembly / Jet Pump Assembly Close up & Pack Traveler checkbox # 4 #8 Traveler checkbox # 3 Traveler checkbox # 4 Traveler checkbox # 5 Assemble boards Peristaltic to plate Pump Assy Build subassemblies .
  • 19. Assembly Drawings & BOM Based on Cellular Flow • Required parts • Assembly notes • Quality requirements & checks
  • 20. Sub Assembly Flow Cellular Assembly Flow & Sequence Chart Main Assembly Flow Build Cell Sterilox tank Power Build Cell & sensor Supply Pack Supervisor OK 7756-1107 7756-1112 7756-1113 Receiving to ship Check Inspection/Parts Supply Sign traveler Build Outlet Build Inlet Base,Fans, Line Cord assembly assembly Cell Power Supply 7756-1126 7756-1109 Sterilox Tank Assembly Quality Assurance Package Unit 7756-1104 & 1128 Start traveler & Checklist Review Traveler initial box # 1 assign serial number Traveler initial box Sign traveler Inlet/Outlet Valve Assembly & Test Burn-In & Test Unit 7756-1125 Traveler initial box # 2 Add test data to traveler Plumbing & Waste Tank Assemble Salt Chute & Front Plate Assembly Electrical Assembly / Brine Tank Top Cover 7756-1110 7756-1119 / Jet Pump Assembly Close Up & UL Test Traveler initial box # 3 Traveler initial box # 4 7756-1100 7756-1111 Traveler initial box Labeling Traveler initial box # 5 7756-1102 Remote programming Tubing Build pH Chamber Build Catholyte Chamber port 7756-1129 7756-1115 7756-1114 7756-1118 Cover assembly U/I assembly 7756-1102 7756-1124 Peristaltic Build conductivity probe Assemble Boards Jet Pump & Brine Tank Pump 7756-1116 to Electric Plate Waste Tank assembly Assembly 7756-1117 assembly 7756-1106 7756-1108
  • 21. Guidelines for Lean Cell Design Each operation is ergonomically designed Machines are arranged in the sequence of operations needed to process the part All operations needed to make the part in the cell and have process time < CT or Takt time Work stations equipped with pokayokes which perform as self inspections Aisle width is 4 ft.
  • 22. Preliminary Cell Layout Follows Cell Flow and Sequence Implementation Planning
  • 23. Questions to Ask About the Value Stream Represented by the Cell Is the operation valuable? Is the operation flexible? Is the operation cycle time within takt time? Are the operations balanced?
  • 24. Verify Design & Cellular Concept Bread Board • Verify design concepts • Parameter Design of Prototypes Experiments Verify design & cell
  • 25. Verify BOM & Material Staging for the Cell Lead time Space Availability Reduce cell assembler material handling Level of Material Control (kanban)
  • 26. Verify Quality System Final Test Work Station Checks Vendor Process Capabilities Documentation Build Customer Confidence!
  • 27. Establish Assembler Knowledge & Training Requirements based on Cellular Design ID S uba sse mbly/Ope ra tion T a nk & Ba se Assy 1 Cell Subassembly 1 X T T 2 Cell Power Supply 1 T X T 3 Base and Tanks 1 X T T Inle t/Outle t a sse mbly 4 Inlet/Outlet Mounting Plate 2 - X T 5 Jet Pump Water in Assembly 2 - X T 6 Process Water In Assembly 2 - X T 7 Output Valve Assembly 2 X X T 8 Assemble/Test Inlet/Outlet Assembly 2 X X T Front P la te Assy 9 Catholyte Chamber Assembly 3 X X X X T 10 pH Probe Assembly 3 X X X X T 11 Conductivity Probe Assembly 3 X X X X T 12 Assemble/Test Front Plate 3 X X X X T E le ctrica l Assy 11 Remote Program Port Assembly 4 T T X X X 12 Electrical Plate Assembly 4 T X X X X X 13 Signal Transformer Assembly 4 T X X T 14 Peristaltic Pump Assembly 4 T X X 15 Sensor Calibration 4 T X X X 16 Cuno Jack Wiring/Soldering T X X T Electrical Component 17 4 T X X Wiring/Mounting P lumbing/ T ubing 18 Side Tubing Connections 5 X T Tubing Interconnection-Aqualox 18 5 X T Tank 18 Waste Chamber & Front Plate Tubing 5 X T 19 Assemble Tank & Pump to unit 5 X T 20 Jet Pump Assembly 6 X X 21 Waste Chamber Assembly 6 X X T 22 Brine Tank Assembly 6 X X T 23 T e st 7 T T X X 24 S a lt D oor 8 T X X 25 Ope ra tor Inte rfa ce / Cove rs 8 T 26 Ground P lug Asse mbly 8 T X 27 Fina l U nit Che ck 8 T T X X 28 Packing 9 T T X T T - Trainer for task X - Trained to perform task
  • 28. Pre-Production Cellular Assembly Flow, Sequence & Quality Chart Sub Assembly Flow Main Assembly Flow Build Cell Sterilox tank Power Build Cell & sensor Supply Pack Supervisor OK 7756-1107 7756-1112 Workstation 7756-1113 Receiving to ship Check Quality Check Inspection/Parts Supply Sign traveler incoming Workstation receipts Quality Check Build Outlet Build Inlet Base,Fans, Line Cord assembly assembly Cell Power Supply 7756-1126 7756-1109 Sterilox Tank Assembly Quality Assurance Package Unit 7756-1104 & 1128 Start traveler & Checklist Review Traveler initial box # 1 assign serial number Traveler initial box Sign traveler CM-19-03- 010 Rev A Workstation Inlet/Outlet Valve Quality Assembly & Test Workstation Check Burn-In & Test Unit 7756-1125 Quality Check Label Check Traveler initial box # 2 Add test data to Final calibration & test traveler CM-19-01-002 Rev A Plumbing & Waste Tank Assemble Salt Chute & Front Plate Assembly Electrical Assembly / Brine Tank Top Cover Workstation 7756-1110 7756-1119 Close Up & UL Test / Jet Pump Assembly Quality Check Traveler initial box # 3 Traveler initial box # 4 7756-1111 7756-1100 Traveler initial box Labeling Traveler initial box # 5 7756-1102 Assembly & Remote programming Workstation Workstation Tubing Quality Checklist port Quality Check Build pH Chamber Build Catholyte Chamber Quality 7756-1129 7756-1118 CM-19-03-012 7756-1115 7756-1114 Check Cover assembly U/I assembly 7756-1102 7756-1124 Peristaltic Build conductivity probe Assemble Boards Jet Pump & Brine Tank Pump 7756-1116 to Electric Plate Waste Tank assembly Assembly 7756-1117 assembly 7756-1106 7756-1108 Note: Green accepted labels will be applied to subassemblies at specified workstations when they pass the go/no-go test and inspection.
  • 29. Transition from DMADV to DMAIC Pre-Production Build & Evaluation Fitting Leak 59 1st 100 Build Assembly Defect pH Control Failure Conductivity Control Failure 37 33 18 70 Overall Defect Pareto Analysis FMEA using Final Test Data Tank Leak 11 59 60 # of Occurrences SV-7 no/too little flow 7 50 37 40 33 30 18 20 11 7 Conductivity Probe 10 10 pH Probe CPU 1 5 0 Service History Fitting Leak Assembly pH Control Conductivity Tank Leak SV-7 no/too Defect little flow Failure Control Failure Inoperable 20 Incorrect assembly Sensor not secure Loose Connections 13 7 5 1st 100 Build Assembly Defect Pareto Analysis Compare data to determine product & Damaged/malfunctioned component 5 Sensor incorrect location 3 14 13 # of Occurrences Other 3 12 10 cell design changes(can 8 7 6 5 5 4 3 3 2 0 establish ratios) Incorrect assembly Loose Connections Sensor incorrect Sensor not secure Damaged/malfunction Other ed component location Customer feedback
  • 30. Pre-Production Cell Design & Flow to Eliminate the Eight Wastes Inventory (more than one piece flow) Overproduction (more or sooner than needed) Correction (inspection and rework) Material Movement Waiting Motion Non-Value Added Processing Underutilized People
  • 31. Changes to Cell Design from Quality & Service Data Reduce Defects & Cycle Time Change design & method of connecting piping fittings & pressure testing to eliminate leaks & reduce cycle time Simplified final test procedure through improved conductivity control Simplified waste tank assembly Vendor to supply wire harnesses
  • 32. Product & Cellular Design Continue in Parallel DMAIC Define & Analyze Cycle Measure • Concepts Cell Cellular Pre-Production Requirements Concepts Cell Verify Design •Breadboard • Prototype • Requirements • Drawings & BOM • FMEA Cellular Assembly Verification Cellular Flow, Sequence, Layout
  • 33. After DMADV: the DMAIC Cycle Six Sigma In Action SDCA Measure & Plan-Do-Study-Act Define Analyze Teams Benchmark Analysis tools SDCA ID variability Employee Involvement Improve Design of Control Plan-Do-Study-Act Experiments SDCA = Standardize-Do-Check-Adjust
  • 34. Lessons Learned Specify everything: fasteners, tube lengths, etc. (or the assemblers will guess) Avoid tight fits. Watch stack up tolerances Understand vendor capabilities Have vendors supply complete subassemblies Need to verify BOMs at each workstation Have assemblers participate in prototype assembly
  • 35. Designing Products for Lean Cellular Assembly Methodology that maximizes value and achieves improvement in….. Customer satisfaction Operating costs Process speed(lead time) Inventory & invested capital Quality Operating flexibility
  • 36. Contact Information Advent Design Corporation Canal Street and Jefferson Ave. Bristol, PA 19007 www.adventdesign.com 800-959-0310 Frank Garcia, Director Engineering Services frank.garcia@adventdesign.com Thomas A. Lawton, President Tom.lawton@adventdesign.com
  • 37. Bill Chesterson CEO Automation & Product Design Advent Design 215 781 0500 Ext: 203 Corporation bill.chesterson@adventdesign.com 925 Canal Street Tom Lawton President Bristol PA, 19007 Contract Manufacturing 215 781 0500 Ext: 202 (P) 215 781 0500 (F) 215 781 0508 tom.lawton@adventdesign.com www.adventdesign.com Frank Garcia Director Planning & Productivity 215 781 0500 Ext: 207 frank.garcia@adventdesign.com