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Efficient Raw Material Management System Design for Pleasant Company Assembly

This project conducted by Matt Van Dyke, Kristin Shuda, Dila Mohd, Jared Hanson, Abir Sarhan, and IE 476 on May 9th, 2000, aims to improve raw material presentation on assembly lines by designing ergonomic solutions and incorporating worker input. Tasks include observation, design formulation, and finalization based on Pleasant Company's feedback and ergonomic principles.

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Efficient Raw Material Management System Design for Pleasant Company Assembly

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  1. Pleasant Company Assembly Material Management Team: Matt Van Dyke Kristin Shuda Dila Mohd Jared Hanson Abir Sarhan IE 476 May 9th, 2000

  2. Overview • Existing Situation & Goals • Tasks Performed • Design Considerations • Areas Addressed • 3 Designs • Comparisons / Recommendation • Questions

  3. Existing Situation • Raw good shelves not conducive to easy resupply • Shelves are not located in an ideal ergonomic position

  4. Our Goals • Design a better system to present raw materials to workers on the assembly line • Focus on raw materials that are common to several product lines • Utilize worker input to finalize design specifications

  5. Tasks Performed • Observed and Worked on the Assembly Line • Observed How Others Were doing Similar Operations – Best Practices • Evaluated the entire line and decided which parts of the system we wanted to focus on • Listed requirements and constraints

  6. Tasks Performed (cont.) • Formulated initial designs from these • Detailed the drawings and made macro sketches of the line to show how the carts would be aligned • Solicited input from management and workers • Finalized designs using Pleasant Company input and relevant ergonomic principles

  7. Design Considerations • Resupply from behind the line • Carts need to be narrower than existing but large enough to hold a reasonable amount of raw material • Shelves as close to the operator as possible without interfering with product on the line • Focus on large volume product lines

  8. Areas Addressed • Existing designs • table/shelf at beginning of line • tilt table • Proposed solutions • table/shelf at beginning of line • non-tilting tilt table • flat cart

  9. Table/Shelf • Table height lowered 1.5” • Shelf height reduced by 2” to 9” above table surface • Shelf depth extended by 2” to 13” Page A2

  10. Non-Tilting Tilt Table • 20” deep horizontal raw material buffer • 60º angled section with 5” lip • 21” width to accommodate 2 stacks of lids or 3 of hard cover books Page A4

  11. Flat Cart • 21” x 24” usable area • Low 47” total height • Highly flexible/simple design Page A8

  12. Comparisons • Flat and Non-Tilting Tilt Table cost about the same • Ergonomic differences negligible (operator preference deciding factor) • Flat cart has lower total height • Tilt Table uses existing materials

  13. Recommendation • Modify one tilt table and purchase one flat cart • Try both at each position • Seek operator input for their preference

  14. Any questions? ?

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