Systematic Analysis to Reduce Raw Material Waste during Changeovers in Length-Based Manufacturing

ABSTRACT: Optical fiber manufacturing is a multiple-step length-based manufacturing process that involves combining individual fibers into color-coded buffer tubes. These buffered tubes are then jacketed to protect the fibers from environmental factors and external loads. The jacketing process is the costliest step in this cable manufacturing process due to the cost of the jacketing raw materials. The changeovers in the jacketing process are optimized from the changeover time reduction point of view. During the jacketing process, if the compound type or color has to be changed, at order completion, the excess compound in the extruder is dumped. This process is called dry bleed-out. There is a potential to reduce the raw material waste associated with changeovers by changing the dry bleed-out process and providing real-time feedback to operators about the costs associated with the compound they are wasting. In this paper, an experiment-based approach to change the process and a heuristic approach to get the buy-in from operators is discussed. ADVISOR: Charlie Purdum, Professor of Practice/Director of Industry Relations, Penn State Robert Voigt, Professor, Dept of Industrial & Manufacturing Engr, Penn State

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Work Title Systematic Analysis to Reduce Raw Material Waste during Changeovers in Length-Based Manufacturing
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Penn State
Creators
  1. Harsh Khandelwal
Keyword
  1. DMAIC
  2. Lean
  3. Length Based Manufacturing
  4. Changeover cost reduction
License All rights reserved
Work Type Research Paper
Deposited April 07, 2020

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