Laser Clean Room Re-design: a Manufacturing Facility Re-layout

2 TABLE OF FIGURES 5 INTRODUCTION 6 Problem Statement ...................................................................................................... 6 Deliverables................................................................................................................. 6 Scope .......................................................................................................................... 7 Plan of Action .............................................................................................................. 7 Report Content ............................................................................................................ 8 BACKGROUND 9 History of the EyeLite and the PurePoint Production Lines ......................................... 9 Servicing Process of the EyeLite ............................................................................... 10 Manufacturing Process of the PurePoint ................................................................... 11 LITERATURE REVIEW 12 Recognizing Potential Areas of Improvement............................................................ 12 Common Area of Improvement: Facility Layouts ....................................................... 13 Why Pursue Facility Layouts? ................................................................................... 14 Systematic Layout Planning ...................................................................................... 15 Phase II: Identifying Process and Material Flow ........................................................ 16 Phase II: Applying Lean Manufacturing Standards.................................................... 18 Phase II: Applying Visual Management Standards.................................................... 20 Phase III: Common Layout Designs .......................................................................... 21 Phase III: Creating a Layout Design .......................................................................... 23 Conclusion................................................................................................................. 24 DESIGN 25 Current State of Laser Clean Room........................................................................... 25 Current State Layout Issues ...................................................................................... 26 Layout Design Requirements and Limitations ........................................................... 26 Design Decisions: Downsizing the Laser Clean Room.............................................. 29 Design Decisions: Sorting the Laser Clean Room..................................................... 31 Design Decisions: Clear Process/Product Flow......................................................... 32 Alternative Layout Designs ........................................................................................ 36 Feedback and Final Layout Design ........................................................................... 36 Implementation Plan.................................................................................................. 37 Cost/Savings Analysis ............................................................................................... 38 METHODS 39 Product Travel Path Simulation ................................................................................. 39 Technician Gowning Time ......................................................................................... 40 Production Floor Input ............................................................................................... 40