Caterpillar Hillsville Visual Plant

Client: John Richardson

Team 38: Travis Gilmer, Edward Dai, Jeremias Cruz-Corniel, Alex Brown

Primary Customer Contact: John Richardson Email: John.Richardson1@cat.com

Advisor: Dr. Bob Sturges

1 Team 38 Statement of Work

Executive Summary:

The project team will develop and implement a Visual Plant database interface. Currently, management has to physically monitor the status of production. This entails putting on personal protective equipment, entering the manufacturing shop floor, and personally inspecting the status of each workstation. The implementation of the Visual Plant will allow management to perform these activities from the comfort and safety of their office.

In order to accomplish this we will gather all the data provided to us, from this we will select any pertinent data and incorporate it into our database. We will use Microsoft Access and Microsoft Excel to create the database and implement it using knowledge gained from classes taken at Virginia Tech. This will be beneficial to you since it will minimize costs associated with creating the database.

Table of Contents

1.0 Technical Plan......3 1.1 Project Overview...3 1.2 Technical Approach...4 1.3 Deliverables...5 1.4 Customer benefits..5 2.0 Management and Implementation Plan....6 2.1 Work breakdown structure6 2.2 Responsibility matrix7 2.3 Incurred Customer Costs...8 2.4 Related Experience8 3.0 Appendix..8 3.1 Special Equipment and Facilities..8 3.2 Customer Description....8 3.3 Technical references..9

2 Team 38 Statement of Work

1.0 Technical Plan 1.1 Project Overview

1.1.1 Problem Definition Caterpillar Hillsville managerial employees need a more efficient way to observe and monitor the progress and status of their production line equipment within the facility floor. Currently, employees must frequently equip safety attire in order to make rounds around their facility to physically check the condition and progress of various machines.

1.1.2 Objectives The objective is to implement a Visual Plant. This will allow management to track the status of the facility from the comforts of their office. Examples of such data as that may be displayed: If a machine is functional Anytime a machine is stopped Machine Utilization Part Yield

1.1.3 Scope 1.1.3.1 In Scope:

Implement a database to display part yield, machine utilization, if machine is functioning and whenever the machine is stopped.

1.1.3.2 Out of Scope:

The degree in which the worker must interact with the database

3 Team 38 Statement of Work

1.1.4 Constraints The team may face challenges on how to connect the machines to the database interface itself. Many of the machines are completely manual. What is meant by this is that some of the workstations only involve a worker fastening/welding a bearing onto a roller. In this situation we will need to develop an electronic means of notifying the database that this operation is in progress. The team will also encounter challenges on how to develop counters that will work in conjunction with the machinery. This will be needed to establish a part yield by every machine.

1.1.5 Functional Requirements

Solution must require a very limited amount of technical experience to utilize.

Solution must viable long term by requiring minimal maintenance. Solution cannot require too much attention from worker personnel for gathering data at the workstation.

Solution requires minimal to no cost.

1.2 Technical Approach The main point of our technical approach is to use database entry methods (back-end) linking to a central database in an office environment. From this, we can expect to see utilization from each area of work in the plant, where each area is split into each sub-process or work station. The worker selects a job or part to work on from the database list, and realtime data will be shown in the office as the back-end is updated. This method allows office workers to see real-time execution of each work order #, and the office can also use the database to check past orders and pending orders. Furthermore, each work station back-end would be linked to an MRP for each day, minimizing worker involvement with the database. Simply put, the worker would only have to start the process and end it as he finishes the job. Again, the database is stored at the end of each day to a server, allowing future access as well as security for the files.

4 Team 38 Statement of Work

1.3 Deliverables 1. Main database system with back ends for each station. 2. Database model of work order system, ie. a form for selecting work orders. 3. Workable interface for each worker to use at their station. 4. Realistic hardware interface, which requires cost analysis 1.4 Customer Benefits The database in the office will display real time execution of work order numbers. This database can be used to check past and pending orders. The database is stored at the end of each day to a server, allowing future access as well as security for the files. Management will be able to track part yield, machine utilization, machine functionality, and machine stoppage.

5 Team 38 Statement of Work

2.0 Management and Implementation Plan 2.1 Work Breakdown Structure

WBS 1 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.4 4.4.1 4.4.2 4.4.2.1 4.4.2.2 5 Task Name Understand project Plant trip to Caterpillar Plant Analyze Problem definition Submit Trip Report Define Problem Definition Identify objectives Identify constraints Develop team charter Submit Progress Report #1 Develop database requirements Indentify number of workstations Develop database requirements Understand plant throughput Determine worker input Identify integration of database into plant Application of database to current system Develop interface for worker Develop interface for management Model links between main database and workstations Test database with "dummy" facility Implementation Test "beta" version Use example work orders in simulation environment Test file storage system over time Present test findings to client Prepare presentation highlighting pros/cons of system Present to client and answer questions Revision of project as per client specifications Prepare and finalize findings for client and symposium Prepare package for implementation at plant Prepare presentation for Symposium Make final revisions to Symposium presentation using results from client presentation Compile final presentation using edits and results Symposium Duration 15 days 1 day 4 days 0 days 10 days 4 days 4 days 6 days 0 days 30 days 3 days 4 days 7 days 7 days 9 days 31 days 7 days 7 days 7 days 10 days 96 days 31 days 15 days 16 days 6 days 5 days 1 day 30 days 30 days 15 days 15 days 5 days 10 days 0 days Start 9/28/2012 28-Sep 9/28/2012 10/2/2012 10/2/2012 10/2/2012 10/2/2012 10/6/2012 10/12/2012 10/12/2012 10/12/2012 10/15/2012 10/19/2012 10/26/2012 11/2/2012 11/11/2012 11/11/2012 11/18/2012 11/25/2012 12/2/2012 1/22/2013 1/22/2013 1/22/2013 2/6/2013 2/22/2013 2/22/2013 2/27/2013 2/28/2013 3/28/2013 3/28/2013 4/11/2013 4/11/2013 4/16/2013 4/26/2013 End 10/12/2012 9/28/2012 10/2/2012 10/2/2012 10/12/2012 10/6/2012 10/6/2012 10/12/2012 10/12/2012 11/11/2012 10/15/2012 10/19/2012 10/26/2012 11/2/2012 11/11/2012 12/12/2012 11/18/2012 11/25/2012 12/2/2012 12/12/2012 4/26/2013 2/22/2013 2/6/2013 2/22/2013 2/28/2013 2/27/2013 2/28/2013 3/28/2013 4/26/2013 4/11/2013 4/26/2013 4/16/2013 4/26/2013 4/26/2013

6 Team 38 Statement of Work

2.2 Responsibility Matrix

RACI Chart
Department: Procedure: Updated: Step 1 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.4.3 1.5 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.4 4.4.1 4.4.2 4.4.2.1 4.4.2.2 5 Caterpillar-Hillsville Visual Plant Database Project 11/02/12 Task Understand project Plant trip to Caterpillar Plant Analyze Problem definition Submit Trip Report Define Problem Definition Identify objectives Identify constraints Develop team charter Submit Progress Report #1 Develop database requirements Indentify number of workstations Develop database requirements Understand plant throughput Determine worker input Identify integration of database into plant Application of database to current system Develop interface for worker Develop interface for management Model links between main database and workstations Test database with "dummy" facility Implementation Test "beta" version Use example work orders in simulation environment Test file storage system over time Present test findings to client Prepare presentation highlighting pros/cons of system Present to client and answer questions Revision of project as per client specifications Prepare and finalize findings for client and symposium Prepare package for implementation at plant Prepare presentation for Symposium Make final revisions to Symposium presentation using results from client presentation Compile final presentation using edits and results Symposium Gilmer R,A R,A A R,A R,A R R A A,I I I I I R,A I I I R,A R R R,A R,A,I R,A R,A R,A R,I R,A R,A,I R,A,I Cruz-Corniel R,A R,A A R,A R R,A R A I A,I I I I I R,A I I R R,A R R,A R,A,I R,A R R,A R,A R,A R,I R,A,I Dai R,A R,A A,R R,A,C,I R,C,I I R,A,C,I A,R R,I R,I R,I R,A,I R,I I I R,A,I I R R R,A R,A,C,I R,A,I R,A R,C R,A R,C,I R,A R,C,I R,A,C,I Brown R,A R,A A R,A R R R,A A I I I I A,I I I I R,A R R R R,A R,A,I R,A R R,A R,I R,A R,I R,A,I

R: A: C: I:

Legend Responsible for perfoming the task Accountable for the task being completed Consulted with prior to the activity being performed Informed that the task has been completed

7 Team 38 Statement of Work

2.3 Incurred Customer Costs Our groups travel costs include only gas fare for traveling 122 miles from Virginia Tech to the Caterpillar plant in Hillsville, which we estimate to be $20 per visit. We are expecting to visit your facility every other week in the initial stages of our project and as often as necessary when we begin implementing our database solution in order to monitor and troubleshoot its performance. Expenses incurred by the resources to develop our online database will encompass providing equipment such as timers and counters at a number of workstations at the manufacturing plant. However, sophistication of this data collecting system may be increased as you may wish to make the system more automated. The cost of having our database online should be minimal considering Caterpillar maintains its own domain server.

2.4 Team Related Experience Experiences for this method include involvement from each team member in a Data Management for Industrial Engineers course at Virginia Tech as well as relatively extensive experience from each member in the field of data management using Microsoft Excel and Access.

3.0 Appendix

3.1 Special Equipment and Software The team does not anticipate the use of any specialized software or equipment.

3.2 Customer Information Our customer supervises a manufacturing plant under Caterpillar Inc. in Hillsville, Virginia. The plant manufactures steel rollers with polymer casings and industrial pulleys. These are then utilized by other manufacturing plants in product assemblies for Caterpillar.

8 Team 38 Statement of Work

The staff must make frequent trips around their facility to physically check the condition and progress of various machines. Caterpillar Hillsville managerial staff needs an improved and efficient way to observe and monitor the status of their production line equipment within the facility. The objective is to implement a Visual Plant. This will allow management to track the status of the facility from the comforts of their office.

3.3 Technical References Technical references include the use of Caterpillar Inc.s website in addition to a PowerPoint project proposal from John Richardson. Notes and slides from the ISE 3024: Data Management for Industrial Engineers, authored by Dr. Shewchuk, are also utilized.

9 Team 38 Statement of Work