Optimization of Large Grinding Cells

Overview

The team was to optimize the efficiency and ergonomics of a manual grinding cell that is used for the finishing of castings. The grinding cell typically includes a 30” grinding wheel, belt sander, slot wheel grinder, and resonance frequency (RF) tester. Parts are typically dumped into a chute that stages the castings for the operator. After finishing the castings and testing it of the RF tester, the good castings are put in one tub and scrap parts are put in a separate tub.

Objectives

The main purpose of the project was to increase grinding cell throughput by optimizing cell layout, ergonomics, and ultimately cell efficiency. To do this the team was to optimize the space while following all OSHA guidelines, reduce repetitive motion to improve ergonomics, reduce noise level, and increase throughput.

Approach

• Met with Urick employees to get a better understanding of their wants and needs
• Received data for the top ten parts that go through the large grinding cells
• Visited Urick to see the current large grinding cell layouts
• Interviewed operators of the large grinding cells
• Took pictures and measurements of all the equipment currently in the cells
• Developed concepts to meet sponsor’s needs
• Got concepts approved by the team at Urick

Outcomes

• The suggested urethane sheeting reduced the noise levels within the cells by 12.06%
• The suggested way to make the equipment easily adjustable accommodates 90% of the working population
• The new layout allows for easy forklift access
• The new layout should also increase throughput
• The layout allows for more storage space, which essentially could be utilized for more work in process (WIP)