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The challenge of this pillar is to be able to design the means for which we have anticipated the problems and obtain a high level of performance upon installation.

Introduction

The challenge of this pillar is to be able to devise means for which we have anticipated the problems. This is to have the installation of the new equipment as soon as possible. OEE high and simplified life follow-up series. This must go through designing equipment that :

  • Make ” naturally” quality. Request to perform simple self-maintenance tasks safely. 
  • Are designed with easily removable and changeable parts. 
  • Are designed with inexpensive parts.

It should be noted that the best indicator of the implementation of this pillar is the fact that 80% of the cost of the equipment is at the development level vis-à-vis the total life cycle.

1 – Define needs

First step, we will define the project schedule. We will focus on 2 elements :

  • Objectives in terms of investments and profitability. 
  • General needs in terms of functionality. We will rely on the first part of the matrix 1 of QFD to define the overall need.

Of course, this data will be accompanied by constraints in terms of time and the various validation milestones.

2 – Define the criteria

In a second step, we will go into more detail and complete the matrix 1 of the QFD. We will define precisely the criteria that will meet our needs. We can also rely on the principles of design LCC (Life Cycle Conception) or LCA (Low Cost Automation), which will allow us to better target our needs criteria.

3 – Identify solutions to meet the criteria

From this stage, we will design our equipment. We will go into the details of the elements based on the matrix 2 of the QFD. Thus, each technical criterion will be translated into solution.

In the WCM methodology, we will compare each of the potential solutions to our Design Check List and the 5 default conditions which will be of interest to design a simple, visual, flexible and reliable equipment. As a reminder, these conditions are:

  1. Are the conditions clear ? 
  2. Are the conditions simple to hold ? 
  3. Are the conditions variable ?
  4. The variability conditions are easily verifiable ?
  5. Are the conditions easy to restore ?

In particular, we will rely on the analysis of EWO and different HERCA to find solutions to recurring problems.

4 – Produce equipment

At this moment, the equipment is being produced. There is still time to be able to debug the details we observe. Depending on our sector of activity and our experience, we will be able to compare the various functions to a standard check-list of our expectations..

5 – Install new equipment

The equipment is manufactured, we will install it on our line. This is another step to remove the “Bug” It should be noted that at this stage, we will be able to start building the standards of use for production and maintenance. We will rely particularly on the supplier who is probably still present.

6 – Do the tests in production

The equipment obtained a first validation out of production. We will perform a series of tests during production. We will validate the first operating standards. Based on our experience, these tests will have to follow an internal qualification standard that represents our “ standard” to ensure the quality of equipment. We will validate :

  • The functioning of Poka Yoké
  • The standard settings
  • The maximum production rate and series
  • The functioning of the control elements : camera, sensor…

It should be noted that it is preponderant to have, before officially launching production, all production standards (standard of adjustment), quality (control, tolerance …), maintenance (list of parts to change, periodicity …) and security (presence of visuals, protections …) to the point. This to avoid unpleasant surprises in production.

7 – To put in production

The equipment is now officially in production. Standards will be improved as equipment and learning progress.

This is also the time to take stock of the project and the gains that we have had through the holding of the method. This experience feedback should enable us to further improve our Design Control Check List.

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