Title: Final Project
Course: Manufacturing Analytics (ATE Central)

Introduction

In this assignment, you will prepare a written report for submission. Your stakeholder for the report is the plant manager who gave you the initial problem statement. In your report, you will need to include visuals, tables, and short paragraphs to clearly and succinctly deliver your findings and recommendations.

Download the dataset that you will use for this project here. Use the skills that you have accumulated in this course and program and identify anything that you feel might be an issue in this dataset. You may use any program that you are familiar with. What are your findings and based off your analysis what is your recommended call to action. Remember your audience and present the information accordingly.

Objectives

- Analyze the initial problem statement from the plant manager.
- Develop visuals and tables to communicate your data findings.
- Write a report that clearly explain your findings and recommendations.

Scenario

Your plant manager was told by the VP of Operations that the OEE for your plant is at 76.8%. The VP would like a plan for how you location is going to improve OEE to be above 85% like the other 5 plants in the region.

Your plant manager has assigned you to confirm the OEE reported by the VP and propose changes that will increase OEE above.

Additionally, in the last two months your plant has been operating on Saturdays to keep up with orders. Production team members are exhausted and want to get back to a 5-day work week. Your plant manager would like you to asses this problem and propose a solution.

The following information is for your reference.

 | Process and Equipment Information |
The factory is outfitted with 3 different injection mold machines. Each machine is constantly supplied with resin beads from a hopper. Plastic parts are ejected from the injection machines onto a conveyor belt that carries the parts to the packaging machines. Each injector has a packaging machine in the line configuration and each packer can process 2.1 lbs of parts per minute.

An injector molding machine typically has a life span of 10-20 years. Injector I-200 was purchased 2 years ago for $365k. Injector I-206 was purchased 5 years ago and Injector I-205 was purchased over 15 years ago. You recently contacted the manufacturer of I-200 and they can sell the same model of injector for the same price and you can expect to get the same performance.

Each injector is scheduled to run 22hrs a day, 5 days a week. 2 hours a day are set aside for scheduled downtime to account for maintenance, breaks and shift turnover. Downtime on average cost $12k/hr and scrap on average cost $8/lb of parts.

The weekly production needs on average are as follows:

- Product ID 104-4728 requires 2500lbs/week
- Product ID 104-4729 requires 2525lbs/week
- Product ID 104-4730 requires 2550lbs/week
- Product ID 104-4731 requires 2530lbs/week
- Product ID 104-4732 requires 2530lbs/week

Injection Molding Information

Process Data:

Injector Molding Process Data FINAL Dataset.xlsx

Machine Data:

1200_Output_data.csv

1205_Output_data.csv

I206_Output_data.csv

Structuring your Report

For your written report, you will be communicating your data findings. As a general reminder, your report should be formatted to include:

- Introduction
  - Paraphrase the problem statement and your assumptions.
- Body
  - What are your findings?
  - Visualizations
  - Description of what the visuals show you
  - Results
- Conclusion
  - What does the data suggest about possible changes to be made?
  - What is your conclusions?

Submit

Project Write Up

Prepare a report that contains the following elements.

1. A current state of the factory and its capacities.
2. Any relevant KPIs.
3. Downtime and Quality reports utilizing the Pareto Principle.
4. An assessment of the maintenance metrics for each injector and recommendations.
5. A proposal of how to ensure order fulfillment, include a future state map, ROI analysis any estimated improvements to KPIs.

You will turn in a report, Excel or Power Bi files, and submit the code that you used to get your answers as a separate file along with your report.

Length is not as important as substance. If you have completely answered the questions proposed, you will not be graded or docked for length.

Project Tracking

Since you will create your projects in programs that are outside of Canvas, you will need to follow state guidelines for remote work. You can do this in one of two ways:

1. TopTracker: Sign into TopTracker and add your time for this and the other visualization project assignments in the TopTracker Project called Data Visualization.

2. Lab: Come to the lab and inform the instructor that you are working on this assignment at the beginning of the time you spend on it. When you finish, inform the instructor so they can note it in the gradebook.

**Make a note on this assignment of which option you chose when you submit it on Canvas.