Intern Presentation 2015: Agilis, Pacel, and Reflexion ProjectsCourtney Paulson
Introduction Courtney Paulson University of Wisconsin-
Madison, Budapest University of Technology and Economics
Industrial and Systems Engineering, Six-Sigma Green Belt Certificate
June 2016 Manufacturing Engineer Intern
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Agilis: Window Cutter and Hub Alignment Fixture Scrap rate: 15%, planarity one of the highest
Mark at pull wire position to aid processes in accurate planarity outputs
Insufficient mark: Process flow chart Ink Study: Find best ink methodology
Testing ink capsules of various dilutions Capsule dry time, percent fallout, part dry time
Solution Slide fixture to cover ink capsule in idle position
Impact Consecutive markings increased Removed need for Sharpies in process Improved accuracy with cameras Changed scrap range for planarity Completion increased yields
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Agilis: Window Cutter and Hub Alignment Fixture Manufacturing Procedure (MP) for
Window Cutter and Hub Alignment Fixture
Updated current MP, added the option of using new fixture Operator reference photos for fixture
steps and fallout conditions Ink preparation methodology Communicated and walked through MP
with operators and engineers for constructive criticism
Results Removed sanding step MP currently in use Reduced number of operators and
fixtures from 2 to 14
Pacel: Wire Stripper and Shoulder Forming Process PQ failed: due to electrode length
variation Reduce variation by targeting the source
Fishbone diagram of all sources of variation
Shoulder forming: pressure levels Tested and measured shafts at different PSI,
process was capable Dissected failed PQ parts
Correlation between electrode spacing length, and the length from tip to core wire insulation
5-factor DOE: distinguish variation factor Angle of cut Homing Location on trigger Insertion speed Pressure on trigger5
Pacel: Wire Stripper and Shoulder Forming Process Results
Speed of entry and location of shaft against trigger
More length tests based on DOE CAD designed track
Solution and Impact Track did not work
Was not adjustable to different French sizes
Didn’t change insertion speed In the process of designing a
measurement die Spot check wire strip length before
movement down the line
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Reflexion Catheters: Component Scrap Reduction Target source of Material Usage Variance (MUV) Process flow diagram: Potential sources of MUV
Results: Kitting: incomplete kits going to production line Material Consumption: over inspection, unnecessary scrapping Material Reconciliation: making assumptions for unreturned items SAP: changes made to account for incomplete kits
Solution and Impact: Smaller adjustments to each process Work in process
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Conclusion New Learnings:
FMEA: failure mode and effects analysis Process flow diagrams for all projects Agilis and Pacel part testing and measurements Analysis of data
DOE: design of experiment where variation is present Pacel 5-factor DOE
Manufacturing Procedure knowledge New perspective on the medical device industry
Goals: Graduate in the spring of 2016 and start career path shortly
after Start a career in the medical device industry (SJM? )
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Thank you!
Questions?
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