Material handling and inventory optimization of plates for lead acid batteries

Project Proposal

Team 18: Shivom Malhotra Stephanie Mathis Manik Sharma Rachot Veganarug

Agenda
Introduction Statement of Need Goals and Objectives Recommended Approach Expected Results Secondary Results Project Management
- Project Cost - Gantt Chart

Introduction
C&D Technologies Leading manufacturer and marketer of electrical storage and power conversion products Over 25 battery families, including more than 300 models and 1700 SKUs Customers include : Banking insurance internet commerce government military transportation industrial applications manufacturing nuclear power plants oil and gas

Introduction
Lead
Casting Post Burn Adhesive Seal

+ Plate handling and storage + -

Pasting Curing Acid Fill Plate Stacking Post/Strap Burning Stuffing

Ooh, that feels good!

Formation

Packing

Statement of Need
C&D Technologies needs a new material handling and inventory solution for their battery plates. Currently the plates overflow from the storage room into other parts of the facility affecting productivity. Our senior design group plans to remedy this problem by creating a standard process for managing the inventory, utilizing the given space, and updating the material handling processes.

Goals & Objectives

Space utilization

Standard inventory process

First in first out (FIFO)

Quick location of needed plates

Better material presentation to operators

Ergonomics
Environmental controls

Recommended Approach
Background
High WIP, no space Dead space No FIFO Material Handling (M/H) not ergonomic

Measuring Current Conditions

IE 386: height, angle, load & Time Study IE 484: process map Spaghetti diagram

Recommended Approach
Goals/Targets
Reduction of manual handling Increase Space utilization IE 386: OSHA conformance for M/H& lead exposure IE 383: FIFO

Analysis
Brainstorming IE 530: Fishbone diagram, Cause & Effect diagram, Pareto analysis Alternative analysis

Recommended Approach
Action Plans
Implementation of solution Check for any errors

Proposed Metrics
Current state vs. Future state Acceptance in the workplace

Follow-Up/Countermeasures
IE 530: Failure mode and effect analysis (FMEA) Check for sustainability

Recommended Approach

Hoshin Kanri A3 Adaptation of PDCA by Kaoru Ishikawa

Expected Results
Inventory Storage Room
Maximum Utilization of Space

Implementation of FIFO
Reduction of WIP Reduction in Lead Time Reduction in material handling

Reduction in Lead exposure

Expected Results
Elimination of metal blockers Significant increase in space on the racks Elimination of inventory at non designated areas

Elimination of any NonValue added activities

Expected Results
Better organization of plates on the racks
Staging negative and positive plates on the same rack Optimal length of the stack of the plates Eliminating variation in the types of plates

High volume vs. low volume orders

Expected Results
Material Handling
Focus on moving inventory downstream
o Versus manage inventory at the staging area o Eliminating Non- Value added activities

Avoiding awkward positions for the operator More ergonomic process

Secondary Results
Implementing a kitting system for the plates
Eliminates variation in the length of stacks Material handling more ergonomic

Environmentally friendly
All lead plates to be staged in the storage room Reduces exposure to lead

Project Cost
Project cost is divided into four main parts Week 1 4 Project Initiation ($7,400) Week 4 8 Data Collection ($15,600) Week 8 12 Defining improvements ($15, 000) Week 12 16 Implementation ($10,000)

Total $48,000

Project Cost
WEEK 1 Team time Time spent by individual members Time spent in group meetings Consultant hours Time spent with the consultant Total weekly cost WEEK 3 Team time Time spent by individual members Time spent in group meetings Consultant hours Time spent with the consultant Total weekly cost Hours 12 6 2 Hours 6 2 1 Cost $600 $200 $200 $1,000 Cost $1,200 $600 $400 $2,200 WEEK 2 Team time Time spent by individual members Time spent in group meetings Consultant hours Time spent with the consultant Total weekly cost WEEK 4 Team time Time spent by individual members Time spent in group meetings Consultant hours Time spent with the consultant Total weekly cost Hours 9 7 2 Hours 11 5 3 Cost $1,100 $500 $600 $2,200 Cost $900 $700 $400 $2,000

TOTAL COST

$7,400

Project Costs

Gantt Chart

Questions?