Challenge ONE

Component Reel Traceability- develop tracking system to allow us to locate every reel of parts in our surface mount manufacturing area.

 

BackgroundVisteon North Penn Electronics Facility manufactures motor vehicle electronics. 

Our Visteon North Penn Surface Mount Device (SMD) machine operators will place an order for a reel of parts.  The order identification that goes to our warehouse contains the part number, date and time of order and the SMD machine requiring the part.  The warehouse delivers the reel of parts to a central location for the SMD line and the SMD machine operator is required to retrieve their own orders.  At this point the reel of parts does not have any specific identifier on it to track it as it gets used in the process.  The only history we have is a high level record of part number, date and time ordered, date and time order filled and SMD machine ordering the part.  If this reel of parts gets moved from the SMD machine that originally ordered it we do not have any tracking.  At a later date we may need this reel of parts for another SMD machine.  The only starting point we have is the original high level record of the original SMD machine to which the reel of parts was delivered.  However, many times the part is not at that original SMD machine and we now must manually look at every reel of parts at every SMD machine.  So, the challenge is to develop a tracking system to allow us to locate every reel of parts in the SMD area.

 

Possible Areas of Research:

1. Inventory Systems

2. Surface Mount components

Visteon’s Expectations

Business Case Considerations – A complete summary that includes data to support your recommendations is desirable.

 

Judging:  Submissions will be judged on the basis of:   

1.        Originality- Is the idea something not already being tried?

2.        Cost- How much will it cost to implement the idea? Is it cost effective?

3.         Viability- Is it realistic to implement the idea?

4.         Problem addressed- Did the proposed idea address the problem?                

 

 

Challenge TWO

Scheduling- Create the most efficient production schedule possible that meets the requirement for shipping products on time.

Background

Visteon North Penn Surface Mount Device (SMD) Scheduler manually creates a production build schedule for the SMD line.  The schedule is manually created and released to the production once a day at 7 am.

 

Several factors go into making this schedule:

1) product required time (PRT) - this is the date and time the product is required to be completed

2) product batch - required quantity of the product that must be delivered

3) product cycle time - time required to make 1 unit of the product

4) product change over time - time required to make production line adjustments to make it ready to run a new product

 

Sample data:

product cycle time

product A, B, C = 50 seconds

product D, E, F = 60 seconds

product G, H, J = 40 seconds

 

product change over time

from (A, B, C, D, E, F) to (A, B, C, D, E, F) = 10 minutes

from (G, H, J) to (G, H, J) = 20 minutes

from (A, B, C, D, E, F) to (G, H, J) = 30 minutes

from (G, H, J) to (A, B, C, D, E, F) = 30 minutes

 

order data effective 9/24/2007 7 am = product, PRT, batch

A, 9/24/2007 7:00 pm, 125

C, 9/24/2007 7:00 pm, 200

G, 9/24/2007 7:00 pm, 350

A, 9/24/2007 7:00 pm, 125

J, 9/25/2007 7:00 am, 125

B, 9/25/2007 7:00 am, 250

D, 9/25/2007 7:00 am, 250

J, 9/25/2007 7:00 am, 125

E, 9/26/2007 7:00 pm, 200

F, 9/26/2007 7:00 pm, 100

H, 9/26/2007 7:00 pm, 350

F, 9/26/2007 7:00 pm, 100

 

The goal is to make the most efficient production schedule that meets the product required time.  Efficiency is gained by grouping together appropriate product batches and reducing the change over time.

            Possible areas of research:

1. Lean manufacturing

2.    Production Scheduling

 

Visteon’s Expectations

  A complete summary that includes data to support your recommendations is desirable 

 

Judging:  Submissions will be judged on the basis of:

1.         Originality- Is the idea something not already being tried?

2.        Cost- How much will it cost to implement the idea? Is it cost effective?

3.         Viability- Is it realistic to implement the idea?

4.         Problem addressed- Did the proposed idea address the problem?

 

Visteon Timeline and Procedures


Registration Forms Submittal (also complete written proposal submittal instructions, below) — Be sure to view the rules, registration and forms. You must submit completed registration forms and contract forms for the Visteon Challenges via U.S. mail to:

Let's Get Real
624 Waltonville Road
Hummelstown, PA 17036

 

by January 25, 2008

 

Written Proposal —You must submit your written proposal in an acceptable electronic format [Microsoft Word (.doc) or simple text file (.txt)]. Please note:  The written proposals should be submitted as a Word document explaining your business case, not PowerPoint slides. 

Power Point presentations do not give the judges enough information to judge.  If separate graphics or scanned images are included in the written proposal, they should be in gif, jpg, or jpeg format. Send your proposal for the Visteon Challenges via e-mail to both  ryoder@visteon.com and lgr@epix.net by January 25, 2008.  Make sure you submit your written proposal to both e-mail addresses.

Oral Presentation — Your team coordinator will be notified during the week of February 25, 2008, whether or not you are selected to give an oral presentation. **The date and location of the Final Oral Presentations for the Visteon Challenges will be announced soon. 

NOTE:   You will be sent directions and an agenda after finalists are selected.

Only finalist student team members and their adult team coordinator are invited to attend the oral presentation finals. Visteon is not prepared to host student family members.

Visteon Awards for Winning Teams —The winning team will receive a team trophy suitable for the school’s trophy case. The runner-up team (if one is selected) will receive a team trophy, and each of the students will receive certificates. All students taking part in the oral presentation will receive a Let’s Get Real T-shirt.