IE673

 Assignment 1 Re-submission

The parts in Red are new

I have fixed the syntax errors in the CIMpgr models

I have added the Panoramic navigation map section

Introduction and Objective

The objective of this assignment is to model the process that Singh Inc. will be using to develop the new Window Insulator Kits in conjunction with Goff’s Enterprises. The Singh Inc. will also help introduce a new process of making the insulation for the kits and the Climate Curtain in house from 100% recycled materials using recycled paper and fiber glass. This will help make the product greener and cheaper by reducing the overhead cost of purchasing insulation from 3M. We will also utilize 100% recycled vinyl to make the sleeves for the Window Insulator kits and the climate curtains. Before we can put this new process is place we will be modeling it using the CIMpgr method developed by Dr. Ranky.

Singh Inc. is working with Goff’s Enterprises to make new reusable window insulation kits using their existing climate curtain technology. The purpose of this process innovation is to minimize cost and energy needed to produce the new window insulation kits. We will be looking at the whole process from ordering materials to manufacturing, packaging and selling of the product. We will be using the Just In Time (JIT) manufacturing process to reduce in-process inventory and the costs associated with them.

Methodologies Applied 

The CIMprg process model breaks down a project as whole into different layers down to their simplest form in order to show the relationship between the different processes involved.  CIMprg models and methods will be used to analyze, design, implement, maintain, and manage the production system. The model systematically illustrates the relationships between the objects, their functions and entities through a set of diagrams broken down into several layers. 

The CIMprg breaks down the process into layers as follows; A0 is the parent layer which includes the following components controls, inputs, resources and outputs. The parent layer is further broken down into child layers such as A1, which is further broken down to layer A1.1, A1.2, Etc. using the layers the different components of the process are documented and the layers are also used to design, analyze, and integrate internal and external components of the system.

Main Body

The CIMprg method was used to model the new manufacturing process for the Window Insulation Kit by Singh Inc. starting with the first layer of concept and planning, A0:

Control:

   C1A0-Customer demand

   C2A0-Time

   C3A0-Budget

   C4A0-Safety Standards

Input:

   I1A0 - Customer requirements, Colors, patterns, etc.

    I2A0 - Sing Inc. requirements, design specifications.

    I3A0 - Research data, existing window insulation kits, different window

     designs and sizes

    I4A0 - Material from Suppliers, Recycled Vinyl material available for  

     production

Resource:

   R1A0 - Goff’s climate curtain technology

    R2A0 - Lenze’s smart motors for automated manufacturing equipment

    R3A0 – Interlake Mecalux automated warehousing solutions

    R4A0 – Datex’s supply chain software

Output:

   O1A0 - Revenue

   O2A0 - Customer Satisfaction

   O3A0 – Minimizing Cost and Energy Using Smart Technology

   O4A0 - High Quality Finished Product

The first layer is the parent layer of the process: A0. The process diagram shows what resource are available, the inputs and controls associated with the concept and planning stage and the outputs we hope to get out of the new process. Click the link below to see Layer 1 A0.

 Layer 2 A1:

The second layer is a finer break down of the parent layer. This shows the design, product development and manufacturing stages of the new production process. This shows exactly what is going into each step and what is coming of it. This will help the managers that are putting the new process in pace understand exactly what needs to g into each step in order to make the new process successful.

Layer 3 A3.1, A3.2, A3.3

The third layer is the further break down of the manufacturing layer. The layer is broken down into JIT Material Purchasing, JIT Manufacturing, and Warehousing and Shipping. This layer shows the resources, inputs and controls applied to each step in the manufacturing process and the outputs of each step and ultimately a high quality, sustainable and green product.

Process Description

Layer 0

Concept and Design – This is the parent layer and the beginning of the new process and modeling. During this step we will be conceptualizing the new process of making the recycled insulation for the Climate curtains and the Window Insulator kit. This shows the inputs, resources, and controls for the new process, and the outputs we hope to get out of it.

Layer 2: 

Design Process – Design the product that is going to be manufactured and sold. Collect research data on Existing window insulation kit and the customer requirements and design a good quality product at a competitive price. The product will use 100% recycled vinyl material for the production of the window insulation kits. The insulation will also be comprised of recycled materials.

Product Development Process – After the final design specifications have been compiled it is time to build a working prototype and test it in real world conditions to see how it would fair. Make design changes if needed. Test the quality that was designed into the product.

Layer 3: Break down of the manufacturing process.

JIT Material Purchasing – We will be employing the JIT purchasing method to minimize purchasing cost and over head associated with large raw material storage. Datex will help in making this possible with their supply chain software. This will make the profit margins better and minimize the GIP.

JIT Manufacturing – We will also be employing the JIT manufacturing method to minimize GIP and costs associated with it and maximize profits. JIT Manufacturing employs the method of producing just when you need the product. This means no unnecessary production and storage GIP and finished goods.

Warehousing and Shipping – This one is self explanatory, process of warehousing and shipping utilizing Interlake’s automated storage and retrieval hardware to minimize labor costs. We will also be using Datex’s supply chain software to manage customer demand and shipping.

Collaboration

Goff's Enterprises - We are collaborating with them on a joint venture to produce insulation for the Window Insulator kits in house from 100% Recycled materials and incorporating recycled vinyl into their curtain making products.

All this made possible with the help of the other 3 supporting companies Lenze, Datex and Interlake Mecalux.

Lenze - We are using their smart energy efficient space saving motors gear drives to fully automate the production process in order to cut down on energy waste and labor costs to make the product greener and cheaper for the public.

Interlake - We will be using their fully automated warehousing solutions to maximize warehousing space and eliminate unnecessary labor costs. Since the entire process from warehousing to shipping will be automated using robotic lift trucks it will be much safer, free from human error.

Datex - We will be using the 3PL supply chain software and hardware to make the ordering, selling, and shipping process streamlined. They supply chain software will also enable us to utilize the JIT manufacturing process to eliminate unnecessary inventory and maximize profits.

GREEN Aspects

Introducing 100% Recycled Vinyl material into Goff’s Curtain making process.

Introducing new process to make insulation of the Window Insulator kits and the climate curtains from a 100% recycled paper and fiber glass. This will make the products GREEN and sustainable and lower the overall embodied energy need to produce the products which help lower the company’s carbon foot print.

Summary

Created a process model for the new company Singh Inc. and its new product Window Insulation Kits, in cooperation with Goff's, Lenze, Datex and Interlake Mecalux. The CIMprg method was utilized to model the entire process from concept to finished product. The CIMprg allows everybody involved in the product development process to see exactly what is need to complete the product development successfully.  Using the CIMprg models as a frame work for the development of the new process will allow it to move along smoothly while documenting the work step by step. The CIMprg allows us to view the whole process together to minimize mistakes and redundancy to make it lean and more cost efficient.

Further Work Needed

More work is needed to breakdown the layers even further account for all the individual activities that need to be performed in order to produce a high quality, cost effective, Green product.

Panoramic Navigation Map

The panoramic navigation map is nice new technology that can go a long way in helping companies in modeling production, shipping, warehousing and other process. The panoramic navigation map can help combine all the different steps and levels in a process into one easy to navigate photo map. This helps immensely when somebody is trying to learn a new process when coming into a new job or different part of the production line. This can be a great tool to train new employees on production and manufacturing process by providing a complete interactive and visual over view of the entire process from start to finish in one easy to navigate panoramic map. This would cut down the training time considerably and the labor associated it with it. Instead of having someone give the new employees a tour it they can just learn through the navigation map.

Bibliography 

http://www.lenzeamericas.com

http://www.datexcorp.com

http://www.interlakemecalux.com

http://www.goffscurtainwalls.com

Ranky, P G: An Object Oriented System Analysis and Design Method (CIMpgr) and an R&D Case Study, CIMware Ltd.. http://www.cimwareukandusa.com 

Ranky, P G: TQM System Modeling e-Textbook:  eLearning Pack ID: IE673-Spring2012-95-35

Discussions Executive Summary March 4, 2012

During the past few weeks several articles were discussed, starting with the article about the failed Russian space probe and its causes. Discussed the articles and what could have been the reason for the failure with the other students from the class. The failure was due to memory chips not being able to with stand cosmic radiation that is apparent in space. The chips should never have been put on the probe because they were not designed for use in space, in fact the manufacturer doesn’t even test for radiation. How could the Russian Space Agency have let this happen, do they not have any testing procedures of their own when it comes to the space craft and radiation testing. Some body at the agency messed up in my opinion.

The next article I discussed with my classmates was counterfeit drugs. Discussed how the FDA should work closely with the manufacturers to tighten the control on drugs coming into the USA. Also it isn’t just drugs that are being counterfeited other consumers goods are as well. I posted an article about counterfeit toothpaste coming to USA that Contains DEG diethylene glycol which is found in anti-freeze and is fatal for humans. Counterfeit drugs and consumer goods are big business and potentially very dangerous for the public. The FDA needs to do a better job of protecting the public from dangerous counterfeit goods. They should work closely with manufacturer to come up with better procedures for testing and identifying counterfeit drugs and other goods.

IE-673-852 DL

Gurpreet Singh