Assembly Part Per Assembly
A Man A Auto B Man B Auto C Man C Auto D Man D Auto
15 15 30 30 60 60
120 120
Weld
Per Min 3
6 3 6 3 6 3 6
production work. Everything will need to be checked over. They will be working slowly and methodically to ensure quality. Assemblies will take 3-5x longer than the standard.
ii. Week 2-3: is the inflection point. This is where it will be apparent whether an operator has the ability to consistently weld patterns. At this point 80 to 120hr.’s have been invested in training the operator. If they are capable of welding, they should be getting faster, and assembly times will be ~60-70% of the standard. Work should still be verified by another operator.
iii. Week 4: An operator should be able to assemble without another operator verifying their work. They should be able to make defect free assemblies at about 85% of the standard time.
iv. Week 4+: The operator will be getting faster at assembly, working closer towards standard times. It may take another 4-6 weeks for the operator to assemble at ~100% of the standard time. Some operators may never be able to hit the standard.
Automated Progression Towards Productivity: i. Week 1: The operator should be able to run quality assemblies on
Assembly Time (min)
6
3.5 11 6
21 11 41 21
Assembly per hr.
10.00 17.14 5.45
10.00 2.86 5.45 1.46 2.86
Cost
$5.93 $3.57
$10.35 $5.68
$19.16 $9.89
$36.92 $18.27
the machine in under an hour of training. Their training will continue as they run quality product. They know how to startup and operate the machine to run existing recipes.
ii. Week 2: It should be apparent by this point whether the operator is a good fit for the type of work they will be doing. They will continue to have questions but should be running the machine at or near the standard operator time.
iii. Week 3: The operator should have a solid understanding of the process and what goes into making a quality assembly. They should be capable of pattern and assembly quality inspection.
• By moving to automation, MPI has recognized a ~200% potential increase over a fully trained operator. • At MPI we are able to capitalize on an increase in capacity of over ~500% in the first 3 weeks of operator training. o This allows us to engage with
our team in more creative ways and focus on personal development. • MPI’s intuitive operator interface has become the primary training aid, drastically reducing the effort and cost of job set up and change over.
2. Reduction in Cost and Time: Automation has reduced the time and Continued on pg 30 January 2024 ❘ 33 ®
Savings/ Assembly
$2.36 $4.67 $9.27 $18.65
Savings/ Part
$0.16 $0.16 $0.15 $0.16
cost to evaluate a new employee for aptitude, attitude and fit within our company culture. Our onboarding process now starts in the wax room, where a new employee is making perfect wax assemblies and outperforming the most talented manual assembly people. a. Furthermore, we have seen an immediate reduction in scrap rates, increased profit margins and decreased lead time. i. Operator efficiency parts/hr. is
based on 3/min (man) and 6/min (auto) over 55 minutes/hour. This is to account for assembly change over. For manual assembly this is much better than any operator will achieve. b. Lower cost results in higher profit margins when comparing work produced via automation versus manual. See Table 1 above. - An increase of 2X throughput - A decrease of nearly 50% of cost - A significant increase in profitability -
Increased ability to win new orders and bid more competitively.
Estimates were made using the following assumptions: • Manual Assembly 3 Weld/Min • Auto Assembly 6 Weld/Min • 1 Min/Assembly changeover time for both • 5% Scrap on manual Assembly
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44
