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CAREER EPISODE 3

INTRODUCTION

CE 3.1

As a student of second last semester of Bachelor’s


Degree, I prepared a work report as an individual on a
title called ‘Continuous Improvement in Production of
Lamination Department’. This last career episode
describes about this work report completed at the
faculty of work placement 2, Jayco, 1 Jayco Dr.,
Dandenong, Australia. The project was accomplished in
8 weeks from Oct 2015 to Nov 2015. I pursued my
Bachelor’s Degree in Engineering Technologist and
specialized in Mechatronic from Chisholm Institute,
Australia. I got constant support from Daniel and
Jeffery and gained training from them.

BACKGROUND

CE 3.2 Nature of project

Jayco Australia, had some issues arising in their


lamination department, it was leading to time wastage
of labor and cost. Jayco is a recreational vehicle products
manufacturer in Australian market. They wanted to
rectify the issue, for this purpose I had documented a
report based on some of these issues. The report was
document to record the tasks performed at the work
placement in lamination department of Jayco. I had to
understand the position and role I was going to
contribute to the company based on the way the
company runs. I was introduced to the company and my
duties, task, timing, and department was assigned to me.
I understood its organizational structures and
responsibility and the manufacturing processes that took
place in lamination department. Problem statements
were identified after detecting the issues and the cause
of its occurrence.

CE 3.3

Lamination process consists of 4 major stages. They are:

Stage 1 – Welding (Framing) – involves cutting the


rails of aluminum or ply, welding them together,
grinding the surfaces and writing chassis number for
identification.

Stage 2 – Filming – fill the frames with Styrofoam, Gal


strips and blocks.

Stage 3 – Pressing – apply adhesive to attach the


frames and put it under press machine.

Stage 4 – Routing – here, it is trimmed and excessive


spots are removed out from the lamination.

CE 3.4 Objectives

The primary objective of the project was to address the


issues arising in the production and to give a possible
and suitable solution that would help to rectify the
problem and help in improving the efficiency of the
production specially in the Saws and Lamination
department. It would also augment the cost. My project
is divided into three different objectives and goals, that
is based on some topics arising in the company after
understanding the its role. A stepping stone is taken
forward towards my primary aim by completing one of
these three goals.

Objective 1 – Full description to PM


(Preventive/Proactive Maintenance) from RM (Reactive
maintenance) and CLPR (Cut List per Run) from BOS
(Bulk Ordering System)

Objective 2 – recommending and suggesting updates


on the drawings.

Objective 3 – Rectifying the misalignment between the


plan, drawings and cut lists.

CE 3.5 The chart of organizational structure

The below chart shows my position for my work report.


It is with respect to my university supervisor and the
departmental manager of JAYCO.
CE 3.6 Duties

 In-depth research and studies was carried out on


lamination process.
 Based on my study, I planned various possible
solution that matched the requirements.
 Presented my objectives and roles to the company
manager for approval.
 Layouts and work plans were made.
 Mathematical calculations were needed for deciding
the sizes of each part/component.
 Learnt how CNC shield is operated and G code is
programmed.
 Performed online and practical testing on the
operating machine.
 Compared various components before selecting
them.
 Prepared various engineering drawing for
implementation of my project with the help of
engineering tools.
 Task was divided into small parts for achieving
higher accuracy.
 Kept good relations with supervisor.
 Reporting the development of the project to the lab
supervisor and coordinator.
 Regular meetings were kept with the manager to
get feedback of the progress.

PERSONAL ENGINEERING ACTIVITY

CE 3.7

I started to work on my first objective where the issue


was that the constant disorder in inventory of the blocks
was causing wastage in labor time and cost. I identified
that the problem was related to the Saws department
and filling section. To rectify this issue, I suggested full
transition to PM from RM and CLPR from BOS. To
investigate the issue, a reverse tracking process was
applied of the root cause. I prepared a process chart that
described all the processes it involved. Machine down
time was noted in the Saws department fur to reactive
maintenance, it was causing delay in schedules. Then the
blocks were not getting delivered on time, so ordering
of blocks was needed in BOS in lamination department,
and in filling section, because of the type and way of
delivery, there was wastage in labor time and cost.

CE 3.8

I then started my research on what exactly BOS and


CLPR are and its function. So basically, from my research
work and notes, I came to a point that BOS displays
limited amount of information in general and CLPR is
more data specific and focuses importantly on each run.
In the current block production system in the Saws
department is making use of BOS i.e. bulk order system
which is the major concern. In such situation, the ideal
mode of production would be using CLPR. I prepared a
flow model for the functioning of CLPR.

CE 3.9

From my investigation and survey, it was found that the


Saws department transitioned from RM to PM and block
production of CLPR to BOS. CLPR increased the focus of
importance per Run and reduces the scrap. It also
optimized the production cost and saves time along
with discarding of manual processes such as stock
monitoring, ordering process and paper work flow. And
by using PM maintenance type, it minimizes the risk of
production delay, and gives more accurate information.
It was found that the employees still suggest RM for use
rather than PM at its on early stages.

CE 3.10

For my second objective, there was a suggestion on


updating the plans as they were too old. So, I decided to
go with that, and it was found that there was wastage of
materials and awning blocks on door side frames. So, I
tried to analyze the issue and find the solution to
increase the efficiency of the production. I made few
drawing using engineering tools to understand the basic
functioning of the side frame and the reason of awning
of the blocks.

CE 3.11

It was found that there was full length of awning of the


blocks at the front and the rear part. And there was
blocks in combination of full length along with top and
bottom. On understanding the situation, it could be
summarized that there had to be an update in the
drawings related to the ongoing activity and the
company had started taking those suggestions. The
possible solutions could be still done by offering the
customers the option of attaching the electric awnings.

CE 3.12

Thus, after proper research and development on each


task and issues, various suggestions were
recommended. For objective 1, I suggested to arrange a
system that records the details of the machine down
times and whenever detected it should be resolved to
avoid disturbance in the flow of production. Pareto
diagram can be established as per the findings of the
machine down times and can be made use to find and
optimize the PM structure. Considering the objective 2,
by organizing a structure that would determine the
extent of blocks can be eliminated and comparisons can
be made between the actual requirement of the block
and measurements for complete unit per Run. By this
way, possibility of wastage can be reduced and the
workload can be minimized which results is efficient and
cost effective production. And in case of objective 3,
there was a gap of communication between the
departments which can be rectified by optimizing the
solid communication system and troubleshooting it by
minimizing the human errors that occur at the planning
stage.

CE 3.13

While, there was a transition period of block production


system, and the blocks were reported at the filling
section wit wrong specifications. To resolve this, was my
third objective. For this purpose, a thorough
troubleshooting was required so that the misalignment
between CLPR, drawings and the plan can be solved. I
studied a sample case and noted my observations and
findings from that. It was found that there was an issue
with the dimensions. They were calculated and
corrected. The wrong specification was reported and
planned for the best possible solution and given to the
concerning department to fix the misalignment issue.

SUMMARY

CE 3.14

I had successfully completed the training and pleased


the company by giving my findings and recommending
them various possible solutions. I constantly reported
them about my progress and maintained a healthy
professional relationship with them. I utilized various
engineering knowledge that I learnt from my degree
course, like project management, engineering
mathematics, engineering CAD etc. these subjects
became the base for my research work. It helped me
understand various concepts easily, so I could suggest
new innovative solutions. This work placement
experience gave me a corporate experience and
enhanced my technical skills. I presented a PowerPoint
presentation and final work thesis that described in
details about my findings and research work.