Stator Build Process Lean-Out
Grant Brann & Julie Shindler Dr. Harold L. Stalford
Chase Kovach & Ramon Torres Dr. Janet K. Allen
Sponsor Advisors: David Seaman & Syed Jamel
PROBLEM BACKGROUND
IMPROVEMENTS
ANALYZE
AUTOMATION
VALUE ADDED ACTIVITIES
• The stator press operation is performed to prevent the stator from rotating when used in downhole operations. • The stator press machine applies a compressive force to the lamination stack resulting in the laminations being in tension with the stator housing so no rotation can occur.
VAR =
Stator
Total Value Added Time 8.07 min = = 7.77% Total Process Time 103 min
IMPROVEMENTS
• The stator press process is currently manual labor Pressed intensive, except for the machine sub-process.
LAYOUT
Laminations
• Reorganize working area and update CAD Model
• Stators are assembled into motors used in down hole oil and gas drilling operations.
PARALLEL PROCESSING CURRENT—1 Technician
SET UP
PROBLEM DEFINITION
STACK LAMINATIONS
INSPECT SLOTS
PRE-MACHINING
SET UP
• Provide complete Process Documentation
DMAIC APPROACH
INSPECT SLOTS
SET UP
STACK LAMINATIONS
SET UP
STACK LAMINATIONS
INSPECT SLOTS
PREMACHINE MACHINING
SYSTEM IMPACTS SPONSOR’S GOAL: 30%
Analyze the System
• Identify value-adding activities
Improve the System
• Process Time, Throughput, Quality, Ergonomics
Control the System
• Update process documentation
PROCESS TIME 21%
CURRENT
PROPOSED
PROCESS IMPROVEMENTS 43%
TIME STUDY
BREAKDOWN OF IMPROVEMENTS Layout
TOTAL TIME
1
Set-Up
4 min 48 sec
2
Lamination Stacking
24 min 47 sec
3
Slot Inspection
7 min 8 sec
4
Pre-Machining Process
36 min 19 sec
5
Machine Operation
8 min 4 sec
6
Post Machining Process
22 min 8 sec
• REDESIGNED INSPECTION TOOL
Parallel Processing
17%
New tool design allows for the Inspecting and Stacking sub-processes to be combined 5% PROCESS THROUGHPUT QUALITY ERGONOMICS PROCESS TIME THROUGHPUTQUALITYERGONOMICS
1 hour 43 min
TIME
FINANCIAL ANALYSIS Initial Investment Savings IRR
STACKING TIME 3 mins 24 secs
Automation
21%
449 min = 49.89 minutes 9 stators
Average = 68 s/ft
Tooling
35%
TAKT TIME
3 ft
IMPROVED VAR FROM 7.77% TO 9.02%
QUALITY 5%
• SPLIT-THREAD BOLT TIGHTENING/UNTIGHTENING
MEASURE
TAKT TIME =
EXCEEDED SPONSOR GOAL BY 50%
THROUGHPUT 17%
TOOLING
TOTAL PROCESS TIME
POSTMACHINING
POST-MACHINING
PRE-MACHINING
Measure System Performance • Time Studies, TAKT Time
NAME
POST-MACHINING
• Organize carts by model rather than by tool type
• Process is labor intensive
SUBPROCESS
MACHINE
PROPOSED—2 Technicians
• Generate 30% Improvement in Stator Press Process
Define the Problem
Lowering and Positioning of Clamps
Mandrel Storage Racks
32 ft 36 mins 16 secs
INSPECTION TOOL
PROPOSED DESIGN
$34,600 $64,826 53%
Improvement Cost New Inspection Tool (6) $18,000 Carts (2) $800 Mandrel Automation $800 Clamps Automation $15,000 Total $34,600
IMPROVEMENTS ALLOW FOR 350 MORE STATORS TO POTENTIALLY BE PRODUCED A YEAR