stained glass mosaic production
Post on 24-Feb-2016
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BLUE BARRACUDAS
SEAN EAGANBECCA WHELCHELMARC MCDONA LD
THOMAS SPURLOCKWILL STUMPNASSER ALI
Stained Glass Mosaic Production
What are our goals?
Create an efficient production systemApply principles learned in IE 200 & 220Work as a team
Production Overview
3 different types of glass must be cut into different shapes to form a flying WV symbol
The pieces of glass are glued onto a piece of plywood
Grout the entire mosaicRefine product and adhere felt backing
Work Assignments
Task Assigned to Time per Mosaic
Total Time
Blue glass cutting
Sean Eagan, Thomas Spurlock, Nasser Ali
9 minutes54 seconds
59 minutes24 seconds
Yellow/White glass cutting
Will Stump,Marc McDonald
1 minute 35 seconds
9 minutes30 seconds
Gluing Becca Whelchel 3 minutes52 seconds
23 minutes11 seconds
Stencil Cutting Marc McDonald 33 seconds 3 minutes18 seconds
Grouting Sean Eagan 10 minutes 23 seconds
62 minutes 18 seconds*Time was calculated using the MOST method
Initial Problem Improvement
1. The grinding process took far too much time
2. Nipped glass would scatter as it was cut
3. Gluing the white glass took far too much time moving one at a time
4. Determining which face of the glass should face up took too much time, and was often inaccurate
5. Cutting glass is the longest and most difficult process
1. Cuts were made more carefully, and cutters improved their cutting skills
2. A box was used so the scattered glass could be quickly recovered
3. Glue was applied to a wide area and many white squares were glued at the same time
4. The dull side was marked so it could be easily identified
5. More people would be set on this task
Initial Problem Improvement
1. Whole mosaics would take longer to make if each glass cutter cut each piece
2. Often too much glass was nipped
3. Loose cut glass pieces were often confused, or misplaced causing recutting
1. The cutters were assigned various different pieces to specialize and cut so the gluers could pull the pieces and complete the mosaics.
2. Gluers would pull the various pieces from the nipper as they needed them, acting as a kanban, freeing a worker to do other jobs that required more attention
3. A labeled board was set up to allow quick identification of the various pieces
Workspace Layoutand Spaghetti Diagram
Quality Control
Grind poorly cut blue piecesUse template to nip yellow glass and tesserae
into same-size piecesUse no more or no less glue than neededCarefully monitor grouting processRemove excess grout
Safety Practices
Goggles must always be worn to protect eyes from glass
Water must always be in the grinding machine, to prevent overheating
Cutter and nipper operators must be trained with the tools
Glass should be nipped down, and away from faces and other persons
Cost Analysis – Overhead Costs
Overhead Costs
Cost / week
Percentage Used
Overhead Cost/wee
k
Overhead Cost/mont
h
Total Cost
Utilities $100 20 $20 $80 $280
Overhead $250 20 $50 $200 $200
Total $480
Cost Analysis – Material Costs
Material Cost Total Needed
Total Cost Cost per mosaic
Glue $4.00 per tube
20 tubes $80.00 $0.08
Foundation Boards
$0.25 each 1000 boards $250.00 $0.25
Tesserae $0.20 per pound
1000 tesserae
$50.00 $0.05
Yellow Glass $10.00 per sheet
67 sheets $670.00 $0.67
Blue Glass $8.00 per sheet
45 sheets $360.00 $0.36
Grout $4.00 per lb. 167 lbs. $667.00 $0.67Total $2077.00* $2.08*
*Assuming no step has to be redone, which is improbable
Cost Analysis - Labor
Labor Type Task Standard Time
Time per unit
Total labor Cost
Labor at 12$/hr
Cutting blue pieces
59 hr 199 sec/unit $702.48
Labor at 8$/hr
Nipping, grinding ect.
101 hr 342.72 sec/unit
$808.82
Total $1511.30
Cost Analysis
Cost/Unit Overhead Cost $0.28/unit Material Cost $1.41/unit Labor Cost $1.51/unit Total Cost $3.20/unit Plus 35% Profit $4.32/unit
Materials $1410.00 Overhead $280.00 Labor $1511.30 Total $3201.30
X 1.35% Revenue $4321.76
- $3201.30 Total Profit $1120.46*
*Assuming all 1000 units are sold
What We Learned
How to create an effective and efficient production system
How to work as a group and solve problems together
How to IE 200 and 220 principles apply to real systems
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