ITW Deltar Model Factory Final Presentation Bri Hollowell

ITW Deltar Model Factory: Final Presentation Bri Hollowell, Tyler Rogers, Jacob Klingelsmith Dr. Aram Agajanian

Presentation Outline ● Acknowledgments ● Sponsor Background ● Problem Statement ○ Need Statement ○ Design Objectives ○ Functional Requirements ○ Design Constraints ● Design Alternatives ● Design Selection ○ Design Matrix ● Proposed Design ● Design Validation ● Conclusions ● Q/A

Acknowledgments The design team would like to acknowledge ITW and Deltar Fasteners for sponsoring the project. The design team would also like to acknowledge Joseph Schneider for being our sponsor contact, all the ITW Deltar employees we’ve shadowed and talked to, Dr. Agajanian for being our faculty mentor, and Professor Bass for teaching the Senior Design class.

Sponsor Background ● Our sponsor is ITW Deltar Fasteners ○ Division of ITW Automotive Group ● Sponsor contact is Joseph Schneider ○ Manufacturing project engineer ● The ITW Deltar factory is in Frankfort, IL ● ITW Deltar makes plastic components ○ Mainly for automobiles

Sponsor Background ● 80/20 rule ● The ITW Deltar is an “ 80” ● Cell A is a “Super 80” ● Cell C is ITW Deltar’s third and least organized production area

Sponsor Background Cell A Cell C Cell B

Need Statement ● Optimize the safety and workflow by in-lining their packaging systems ● Standardizing the packaging systems of cell C and moving the packaging systems to the outer aisles of each machine ● Current setup Packaging Table Part Exit

Need Statement Walking path for operators Machine w/o packaging system Aisle for mechanics

Design Objectives ● Ergonomic Improvement/ Safety ○ Eliminate picking boxes off from the floor ○ Create safer path for operators ● Simplify Movement for Operators ○ The simplest path is a straight line ● Cost Implementation ○ Minimal cost to design implementation

Functional Requirements ● Primary functional requirement is to be an in-lined packaging process ○ An improved REBA score ○ Minimize packaging times ○ Simplifying and shortening operator paths traveled by moving the packaging systems out to the aisles ● Secondary functional requirement ○ Avoid conflict with mold change and production scheduling ■ ≈14 components a minute ■ Shouldn’t require much setup or maintenance

Design Constraints ● Any blowers or systems with high-velocity parts must be covered to protect the safety of the workers ● Shapes and sizes of part ● Space restriction between machines and walkways ● System can’t block any electrical panels, fire extinguishers, or aisles between machines

Design Alternatives ● Horizontal Conveyor and Scale, Part Container/Scale, or Part Diverter ● “ZEE” Conveyor and Scale, Part Container/Scale, or Part Diverter ● In-Line Box Filling System by Cycle Count

Design Selection ● REBA Score ○ This is a measure of safety in which a number rating is given to each body part movement according to the degree of strain in the movement. The lower the number is, the safer the movement is ● Packaging Time (min: sec) ○ This is from the moment the floor technician first grabs the box being loaded to the moment they release the packaged box on the pallet ● Walking Distance (feet) ○ This is the distance from the mouth of the machine to the pallet ● Cost ($) ○ In regards to the individual cost of machines and the overall of combined processes

Design Selection

Design Matrix

Design Matrix

Proposed Design ● In-Line Box Filling System by Cycle Count ○ A “ZEE” conveyor which automatically fills multiple boxes before needing a floor technician

Proposed Design Machines 413 -401 Machines 316 -301

Design Validation ● ● ● Improve REBA score Improve packaging time Reduce walking distance Cost under 21 K per machine Follow safety guidelines ○ Any systems with high-velocity parts must be covered to protect the safety of the workers ○ Space restriction between machines and walkways ○ System can’t block any electrical panels, fire extinguishers, or aisles ● Avoid conflict with mold change and production scheduling

Design Validation

Conclusion ● Benefits to clients and users ○ More efficient work environment reduces cost ○ Safer work space for the technicians ● Recommendations/ Future steps ○ Uniformity in packaging systems within Cell C

Questions?