Assembly fixture inventory Report presentation

Excellence in Execution

Schlumberger-Private

Project : Assembly Fixture control and conventional naming Team Leader: Valeria Cabriales

Team Members:Carlos Aragon.Adrian Sanchez de la CerdaSergio Torres Alvarado

Managers:John Tufts - MSS-CA PLMRamiro Baez – Technology Manager

Quality: Omar Sangabriel – QMS CoordinatorEsau Garcia - Quality Plan Control EngineerAngel Ramón Medellin López

Finance Controller : Lupita Jesus

LSS Support : Juan Angel Lopez Franco

Project finish date :



Personal Introduction

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Valeria Marisol Cabriales Garza.

Mechatronic engineer student at,Facultad de Ingeniería Mecánica y Eléctrica (UANL)

Academic experience: Academical exchange: Dresden, Germany (July 2014- July 2015).

Professional experience:OSRAM Regensburg Germany (January 2014- July 2014)Optosemiconductors industry

LabView programmer Intern (testing and projects development).

Preh de México (August 2014-December 2014)Plastic injection for automobile industryMaintenance Intern.

Schlumberger CMPU (January 2015 – actual )Completions accessories Manufacturing Intern, Multistage.



Project Background An assembly fixture is a tool to perform an acceptance test. There are many different types and designs. They can be stated on GEMs.

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Project BackgroundCribmaster is an inventory database.

Kits (relation between the part number and its corresponding fixtures)

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Project Background 1,577 folders of fixtures drawings on the local server, “PJF####”. Fixtures for machining and assembly are mixed in the same server file.

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DefinitionD

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Business Objectives:― On Time Shipment― HSE ― Quality

KPIs to measure impact:― OTS― Fixture Inventory

SCOPE: ― Assembly

MMS-CA

HSE

Quality

On time shipment

Inventory



Process Map of a fixtureD

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Customer Demand

Part Number

ME’s

Planning

Search inventory of fixture

New Fixture design Production Quality

Assembly and

functional test

Pressure test

Assembly

Next Operation…



Problem /Opportunity Fixture’s nomenclature and control process are not standardize. It is not stated which fixture to use for a particular assembly

therefore time wasted during the search of fixtures. Non unified process between SC, MSS and LH Duplicated fixtures on inventory. Lack of fixture at the moment of the acceptance test

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Measure – Process Map

Adexa Assembly demand

Design or buy

new fixture

Perform the

acceptance test

In-house or vendor fabrication

Process map before Project implementation.

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Planning

EM’sYES

NO

YES

Does a Fixture is required?

Fixture on

GEMS?Cribmaster

NOSearch

adequate fixture

NO

No action required

YES



Measure – Process Map

Adexa Assembly demand

Design or buy

new fixture

Perform the

acceptance test

In-house or vendor fabrication

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Planning

EM’sYES

NO

YES

Does a Fixture is required?

Fixture on

GEMS?

Search on Cribmaster Inventory

NOSearch

adequate fixture

NO

No action required

YES



Measure - Quantity of Fixtures per type

Drift Bar (OD /ID)

26%

Rod Bar2%

Test Sleeve3%

Test plug24%

Test cap15%

Bore seal18%

Expander (hp body)

1%

Landing Nipple 6%

Spacer4% Nut

1%

Drift Bar (OD /ID)Rod BarTest SleeveTest plugTest capBore sealExpander (hp body) Landing Nipple SpacerNut

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Types of fixtures



Analyze

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Lack of fixtures at

the moment of

the test.



Analyze

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Problems/Root Causes SolutionNo ownership of fixtures assignation process.

Implementation for assembly fixture control procedureIndividual method to assign fixtures

No standardized procedure to register fixture on data base

No accurate information that describe the fixture

No restrictions for duplicated fixture

Fixture inventory reportTime wasted while searching the corresponding fixture

Inventory status is not complete reliableFixtures failure Validation of fixtures



Improve

New Assembly and test fixtures control procedure DMS#101895158.

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RELEASED



Improve - Procedure content

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Assembly fixtures

Funcitonal test

Landing Nipple

Pressure test

Test plug/cap

Test cap (premium thread)

Test plug A

Test plug B

Bore seal plug A

Bore seal plug B

Rod bar Nut HP body (expander) Test sleeve

Drift test

Drift bar

OD Drift bar (external diameter)

ID Drift bar (Internal

diameter)

Fixture categorization.



Improve - Procedure content

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Fixture example nomenclature.



Improve

Example of a faster search:

Thread type : 1.750-4 stub acme

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Improve – Assembly fixtures process map

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- Define if a fixture is required- Search adequate Fixture




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- Compatible fixture or new design- Sustaining validation




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- Add fixture information to cribmaster




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- Verify fixture inspection




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- Purchase or machine a fixture



Improve

Standard work instructions (SWI) :―Register a new fixture in cribmaster (AT-49).―Register a kit of fixtures in cribmaster (AT-50).

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AT-49 AT-50RELEASED

RELEASED



Improve

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Actual status of fixtures on cribmaster

Drift Bar (OD /ID)

26%

Rod Bar2%

Test Sleeve3%

Test plug24%

Test cap15%

Bore seal18%

Expander (hp body)

1%

Landing Nipple 6%

Spacer4% Nut

1%

Drift Bar (OD /ID)

Rod Bar

Test Sleeve

Test plug

Test cap

Bore seal

Expander (hp body)

Landing Nipple

Spacer

NutI

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Control

Assembly and Test Fixture Control procedure Standard work instructions Assembly fixture report Meeting and indoctrination sessions

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Project CostsCost and benefits calculations

Project: "Assembly Fixtures control and conventional naming"

Savings calculations (time saving)

Time searching (before)Time searching (after

improvement)New kits registered on

2015 Fixtures average per kit ME's hour cost Subtotal saving

1:00:00 0:10:00 81 2 $ 22.50 $ 2,187.00

Cost calculations

Hours Hour cost Subtotal cost

40 22.5 $ 900.00

Total calculations

Subtotal saving (time searching) Total project cost TOTAL

$ 2,187.00 $ 900.00 $ 1,287.00



Project Benefits:

― Faster search of fixtures― Avoid any extra inventory ― Accurate information about fixture characteristics ― Planning activities are done before production dates ― Improve 16% of lack of fixture― Improve 66% fixture process flow for CA― Creation of 92 kits until today.― Could be used by the 3 PL.



Next Steps

― Continuous improvement of the inventory report― Migrate fixtures to Gems― Reduce the variety of fixture designs



Knowledge gained…– Drawings interpretation.– SWI, visual aid, process map, procedures development. – Machining, testing and Assembly process– Time management– CI projects development



Question and answer section

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Thank you!



Measure Total number of kits of MSS part numbers until 2014: 233 kit’s Average per year: 38 kitsM

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55 53

22

64

Number of Kits per yearNumber of Kits per year



Definition Catalog of fixtures has very varied options.

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Test plug B Test plug BRod Bar

Test plug B

Bore seal plug B

NutSpacer

Test plug B Bore Seal plug B

Test plug B Configuration

Mixed Bore Seal Plug B/Test Plug B configuration

Bore Seal Plug B configurationBore Seal plug BBore Seal plug B

Rod Bar

SpacerNut Nut



Project BackgroundThe (F.A.T.) factory acceptance test:- Drift test - Functional test - Pressure test

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Assembly fixture inventory Report presentation

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