ProSurge Kaizen Project

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ProSurgeKaizenProject
ProSurge

• Surge Protector Assembly
• Improvement

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(No Transcript)
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Team Members

• Keith M. Houston-Introduction, Goals, Flow Chart
• Ananth U. Gadiyar-Existing and 7 Alternative
  Concepts
• Balasaptadri J. Vellore-Evaluation and Proposed
  Concept
• Jacob Chen-Cost Justification and Conclusion

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Surge Protector Picture
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Presentation Contents

• Introduction to the Project
• Goals
• Flowchart
• Existing Design and Process
• 7 Alternative Concepts
• Evaluation
• Proposed Concept
• Cost Justification
• Conclusion

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Introduction to the Project

• Kaizen revolves around continuous improvement and
  change. The focus is on eliminating waste in all
  systems and processes of an organization. We
  chose to improve the assembly of the surge
  protector because we noticed many things we can
  improve in the device.

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Goals

• Reduce Cost 25
• Reduce Assembly Time 15
• Minimize Space 30
• Develop 1-Piece Flow
• Implement Pull System

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FlowChart
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Existing Design and Process
1. Insert Cord into Base. Reset Switch.
2. Assemble Socket to Base.
3. Connect Green, Black, White Wires.
6. Snap the Wires Together.
7. Close the Assembly
4. Insert LED Assembly
5. Insert Switch
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Alternative Concept 1
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Alternative Concept 2
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Alternative Concept 3
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Alternative Concept 4
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Alternative Concept 5
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Alternative Concept 6
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Alternative Concept 7
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Process Evaluation Rating
Element of Rating 5 Excellent 4 Above
Average 3 Average 2 Below Average 1 Poor NA
Not Applicable X - Unacceptable
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Concept Evaluation
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Concept Evaluation
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Concept Evaluation
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Concept Evaluation
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Evaluation Summary
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Alternative 3 Step 1
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Alternative 3 Step 2
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Alternative 3 Step 3
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Alternative 3 Step 4
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Alternative 3 Step 5
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Alternative 3 Step 6
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Timing Table (seconds)
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Comparison
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Cost Justification
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• Cost of new molding machine - 50,000.00
• Cost of new die -
  10,000.00
• Savings in material - 0.50 /
  unit
• Savings in throughput time - 224 secs
• Savings in labor - 6 workers
• Savings in scrap and rework - 30.00 /day

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Information

• Demand per day 500 units
• One 8 hr shift per day
• TAKT Time 86060/500 57.6 sec
• 240 working days per year
• MARR 20

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Savings per year

• Material Saving 0.5500240 60,000.00
• Scrap and rework 30.00240 7,200.00
• Labor cost 24086(140)10.00161,280.00
• TOTAL SAVINGS 228,480.00

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Cash-Flow Diagram
5,000.00
228,480.00
228,480.00
0
1
2
3
4
5
6
7
60,000.00
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Effective Savings

• The effective savings per year is
• 212,223.00
• Using the UAC method

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Conclusions

• The proposed method would
• Reduce Cost 22
• Reduce Assembly Time 66
• Reduce Space 50

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Conclusions (cont.)

• The proposed method can achieve the customers
  demand with only one shift.
• The proposed method can save the company
  212,223.00 a year.
• The proposed method can save the company 1.77
  per unit.
• We propose, then, the marketing people can use
  the information for the marketing strategy.