The Computer Integrated Manufacturing Laboratory is a constituent laboratory of the Institute for Systems Research at the University of Maryland.

CAD/PAD Lean Manufacturing Study

Participants

Mr. Charles Carr, Dr. Jeffrey W. Herrmann, Mr. David Rizzardo (University of Maryland); Mr. Darrin Krivitsky, Ms. Katie Macey (NSWC, Indian Head Division)

This research was sponsored by the Center for Energetic Concepts Development and the Naval Surface Warfare Center, Indian Head Division.

Project Objective

This project studied how lean manufacturing principles can improve CAD/PAD manufacturing operations at the Naval Surface Warfare Center, Indian Head Division.

Approach

Beginning in the fall of 2002, the participants conducted an in-depth study of the manufacturing process for a particular device (the cutter shown below). Darrin Krivitsky and Katie Macey from CAD/PAD Manufacturing Division participated in project. The project team visited all steps of manufacturing system to collect data by studying sample parts, reviewing part drawings and standard operating procedures, creating charts of process flow, videotaping operations, drawing workstation layouts, and questioning operators.

After analyzing this process, the project team identified opportunities for improving CAD/PAD manufacturing operations in Buildings 286 and 1913 (see Primary Recommendations below). These improvements, which would reduce the labor requirements per unit by 80%, would affect manufacturing operations for the entire set of delay cartridge and impulse cartridge programs (estimated demand for these programs is 24,000 units per year). The project team made specific suggestions in the areas of design for manufacturing, equipment, tooling improvements, employee organization, and safety and housekeeping. In addition, the project team estimated cost savings (see Anticipated Benefits below). Indian Head collaborators validated these results, and the project team gave a project briefing on February 4, 2003.

Primary Recommendations

1. Create two manufacturing cells for manufacturing this product family and install leak test, right-sized X-ray, demag, demag test, and auto-weighing equipment (see layouts below).
2. Consolidate operations and support activities in one building to achieve goal of world-class manufacturing

Anticipated Benefits

The estimated annual savings are $2,215,000 in the first year and $2,770,000 in each subsequent year.

Implementation

Indian Head and University of Maryland personnel have begun a reengineering project that will implement the suggested lean manufacturing improvements in Buildings 286 and 1913. The objective is to develop world class manufacturing processes, reduce manufacturing cycle time, and improve tooling and quality.

Last updated by Jeffrey W. Herrmann, April 25, 2003.

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