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