David Scherpf Capstone Project Abstract

Due to changing emissions regulations, the diesel power unit utilized on a truck-based under-bridge hydraulic platform (HPT) needed to be replaced to remain in compliance with Federal law. This forced change presented an opportunity to learn more about what adds value to the product for customers. Moreover, it allowed for redesigning aspects of the power unit system to reduce cost and provide a better product. The objectives were to better understand which features are critical-to-quality, maintain the current level of system performance, and reduce cost, lead-time, and labor hours associated with the power unit subsystem.

This project followed the DMAIC process for improving the HPT’s power unit. During the Define Phase, operator focus groups and an assembly team Kaizen event were used to create CTQ matrices and a Kano chart to identify areas for improvement. The Measure Phase saw the development of KPIs and a component selection criterion for which factors would justify the project a success. During the Analyze Phase, the gaps from the current to future performance were explored to understand how the system was functioning and what needed to change. In the Improve Phase, setup reductions, poka-yoke assembly parts, and implementation plans were developed to streamline the process. The Control Phase included developing the standard work procedures, engineering assembly drawings, and a control plan for ensuring the new procedures were followed and would become routine.

Throughout the process it became readily apparent that the many areas of improvement would result in large reductions in cost, lead time, and labor hours. The operator and customer feedback resulted in a realization that the existing system was providing more capability than any customer had a need for and, in most cases, would go unused completely. Once the new power unit specifications were worked out, a local supplier was selected to deliver a prototype unit to ensure the system performance would be maintained. The prototype power unit cost $7,000 less than the existing with production units expected to be $8,000 less on average. This represented a 46% reduction in power unit cost. Production lead times were reduced from six months to less than two months, which, for such low volume, is a welcome change. Assembly labor hours were reduced by 50% through setup reduction and a standardized design. The project was considered a success within the company and is a case for using LSS to improve other areas of the HPTs.