Fabric Shredding Process and Facility Design

Transcription

1 Fabric Shredding Process and Facility

2 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Emergency Meeting Week 11 Future (MSD II)

3 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Project Launch Major Points: Met with team Developed norms and values Understood Project Readiness Packet Built relationship with customer Learning Points: Research Shredding process Existing systems/companies Brainstorm/develop milestones Takeaways: Developed: Problem statement Stakeholders Customer questions Bottomline: Researched topic and gathered a basic understanding on the project and deliverables.

4 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Problem Definition Major Points: Preliminary Schedule Scope defined Engineering Requirement introduction Work Breakdown Structure Meeting Powerpoint Meeting Notes Learning Points: George Mason will have some insight onto final product to be produced Further research into the shredding process needed Takeaways: Scope defined as a complete production line per George Mason's recommendation Change needed to Engineering Requirements Rochester based location ROI stated as 5 years or less with the goal of >=$0.32 per pound Bottomline: Further research into the details of the process and machinery is required

5 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 System Major Points: Engineering Requirements Functional Decomposition Benchmarking Risk Assessment Learning Points: George Mason s report and its impact on our scope Research on subsystems and possible equipment Takeaways: More research needed to determine if cleaning and automated sorting machine are options Automated bale machine is most effective Space requirements needs more research Bottomline: GM report doesn t affect our research. More specific and in depth research needed.

6 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Subsystem Major Points: Finalized Engineering Requirements Subsystem Identification (Sorting, Shredding, Baling) Initial Cost Breakdown Tool Learning Points: Further research into subsystems is needed Meeting with Qian Song from Saunders College of Business Cost Accounting 101 with John Kaemmerlen Takeaways: Cleaning step is eliminate (but space needs consideration) Multiple suggestions for Cost Tool Meeting Powerpoint Meeting Notes Bottomline: Cleaning eliminated. Research specific details and associated costs for subsystems.

7 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Emergency Meeting Major Points: The lack of an end product restricted progress Team struggled to get answers from contacts Developed/discussed options to move forward Learning Points: Bonded Logic appeared to be the model of success The concept of fluff may be an intriguing stopping point Takeaways: Insulation is a viable path to pursue Keeping flexibility in the system is still a priority Bottomline: Project focus was narrowed. Insulation was chosen as a end product.

8 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Cost Analysis Evolution of the Cost Tool: Basic model with user inputs page Library functionality Overall Cost Tool (Future Slide 17) Takeaways: Remove financing option and replace with depreciation model Prioritized list of tasks to complete Include more visual aids (Graphs and/or Charts) Create a more user friendly interface Bottomline: Create a robust tool to guide machine selection and evaluate project costs

9 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Future (MSD II) Emergency Meeting Week 11 Today Insulation as an End Product: Overall Process Chart for Insulation Potential Value Streams Recommended Sorting Discuss Plans for MSD II Bottomline: Update with most current information since Emergency Meeting in week 11

10 Insulation Process

11 Potential Sellable Items at Each Step Receiving Sorting 1. Whole garments 2. Jeans 3. % Cotton 4. None Cutting 1. Rags 2. Clippings Shredding 1. Fibers 2. Various shredded sizes Remanufactured Product *By this point in the process, the product could be sold as raw material or remanufactured Baling *Required step for nearly all sold products Mixing 1. Fibers 2. Various shredded sizes Cording 1. Fibers 2. Various shredded sizes *Same as shredding just a better consistency *First step in making any additional products

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13 Week 0 Week 3 Week 6 Week 9 Week 12 Week 15 Project Launch Problem Definition System Subsystem Cost Analysis Today Emergency Meeting Week 11 Future (MSD II)

14 MSD II What would WOW you?

15 Overall Goals Simulation CAD Layout Cost Tool Final Report Concluding May 7th, 2015

16 Simulation Vision A 3D animation depicting the shredding facility Flow of textile, people and equipment in the facility Benefits A Simulation will help determine: Throughput WIP Staffing per shift Downtime / Waiting time Will allow calculations for more accurate ROI Next Steps Quickly evaluate alternatives Takes variation of machinery and people into account Predicts line performance Reduce risk Maximize impact of the investment

17 Facility Layout Vision An layout showing: Machine footprint Empty space Space utilization Flow of raw material, people, and finished goods Drops for electricity/air/other Benefits Next Steps Identify machine footprint requirements Power drops Computer stations Scrap bins Create size categories to add options to layout Identify material handling system Create starting layout of each size category Possibly test with cardboard placeholders Determined machine location Visual of flow through facility Distances between stations Where everything is located in relation to the other How much space is required for necessary processes

18 Cost Tool Vision A user friendly tool with 5 tabs, each having specific functionality 1. User Instructions Tab 2. Machine Library Tab 3. Machine Selection 4. Overall Cost 5. Background Tab Benefits Complete handoff Easily adjustable Comparison tool Machine recommendations for future analysis Maximum flexibility Next Steps Add new machines that we identified as part of the process Carding Machine Mixing Machine Make the tool more robust Add more costs (Ex: Transportation) Implement depreciation function Add graphs of important metrics Update the User instructions

19 Final Report Vision The final report will contain: 1. Abstract 2. Summary of Phases 3. Results & Discussion 4. References Benefits Organizes all project information into one place Ensures Goodwill understand where information came from / was calculated Will provide Goodwill a start for future business cases Next Steps Watch as the project develops Keep this as a continuous project activity As pieces of the project move forward, this report will be updated

20 Gantt chart of MSD II S Simulation Identify process/line Obtain specifications and constraints Final simulation Analysis AutoCAD Identify machine layout requirements Select conveyance system Basic layout Final layout Cost Tool Identify all machines Add in depreciation functionality and finish library component Finalize Cost Tool Add Graphs of important data/metrics Complete user instruction tab Final report Meeting to determine what to include in paper Finalize paper Executive Summary Identify key components to include from report Finish summary

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22 Questions?