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Texas Center for Applied Technology

Texas Engineering Experiment Station

Best Practices - A Contractors Perspective at Corpus Christi Army

Depot

Texas Engineering Experiment StationThe Texas Center for Applied Technology

Victoria C. TorresEsau Perez

Dr. Jerry Congleton, P.E., C.P.E.Dr. John Ayala, P.E.

Prasant Chhotu, MSIE

March 10, 2004


Texas Engineering Experiment Station2 - TEES/CCAD Proprietary Information

What is ERGONOMICS?



According to the DoD Ergonomics Working Group…..

• “The planning and adapting of equipment and tasks to promote the comfort and efficiency of workers.”

• Gains from such changes will lead to:• Improved Production• Product Quality

• Decrease costs associated with:• Absenteeism/Lost Work Days• Turnover• Training• Replacement



DoD Ergonomic Working Group Program Goals:

• Improve productivity and quality• Prevent WMSDs and related injuries and illnesses• Improve the health and well-being of the worker



Who is Responsible?

“NONE OF US IS AS SMART AS ALL OF US”

CCAD Ergonomic Committee

Safety & Mgmt

Shop Personnel

DoD Ergonomic Working

Group

USACHHPM

• Everyone needs to be involved

• All levels of the organization affected

• Promotes participation and “belonging”

• Synergy: When all systems are cooperating, the whole is better than the sum of all its parts.



Current Situation at CCAD

• Lost work days reported cases almost doubled from FY01 to FY02• Workers not aware of basic ergonomic knowledge• “Ergonomic Committee” in development• Methods & Standards developing method

improvements/lean/ergonomic solutions• Ownership of implementation has proven difficult



TEES/TCAT Involvement

• Over the last two years, TEES/TCAT has been on contract at CCAD developing time standards for Methods & Standards Branch - PMD

• At the same time TEES/TCAT has:• Developed integrated video presentations on CDs for management

highlighting concerns: • Directorate Supervisor• Branch Supervisor• Safety Department Personnel• Methods & Standards Supervisor• Engineering Department Supervisor



TEES/TCAT Involvement (cont.)

• Presented suggested solutions to eliminate, prevent and/or decrease identified medical, ergonomic, safety & health, lean, quality and FOD concerns

• Developed economic cost benefit and cycle time reduction analysis for justifying capital investment



Evaluated Shops

• Representative Examples: (UH-60, AH-64, CH-47, etc.)• GE T-700 Engine Disassembly & PSA• Blade Shop• Rubber/Upholstery Shop• Rotor Head Shop• Transmission Shop• UH-60 Assembly Line - AMG• UH-60 Assembly Line - Sheet Metal, Electrical &

Avionics



Lost Productivity

• Method Improvements identified suggested solutions to eliminate, prevent and/or decrease different concerns such as:• Medical • Ergonomic • Safety & Health • Lean Manufacturing• Quality • FOD



Lost Productivity

Work Center Title Time Savings Equipment Cost Cost of AnalysisPayback Period

(Days)1 Year

Savings

527D0, 527E0, 527F0

UH-60 Electrical Repair 30% - 42% 18,574$ 25,000$ 53 $302,245

533A0 Blade Shop 27% - 44% 9,581$ 42,800$ 7 $2,915,614536D0 Rotor Head 18% - 40% 45,490$ 42,800$ 103 $312,889

536B0Transmission

Shop 28.5% - 44% 25,490$ 15,000$ 26 $560,400524A0 524B0 524D0 524E0

UH-60 Assebly line (AMG Trade) 27.1% - 38.2% 158,622$ 51,100$ 58 $1,327,116

524A0 524B0 524D0 524E0

UH-60 Assembly line (Electical,

Sheetmetal and Avionics Trades) 1.60% 8,784$ 51,100$ 253 $86,400

542F0Fuel Control

Shop 15% - 23.2% 22,460$ 42,800$ 21 $1,125,835552B0* Engine Paint 14.4% - 31.4% 3,070$

5TDB0*Transmission

Dissy. 14.3% - 24% 2,920$ 552A0* Plating Shop 20.7% - 26.4% 8,285$ 5UFE0* Upholstery Shop 33% - 62% 31,026$

Total 334,302$ $6,630,499

$6,630,499 is a conservative low end savings estimate*Last 4 shops are missing. Historical Data can not be retrieved for cost analysis

ROI ANALYSIS

Potential Cost Estimate: $6.6 Million Benefit from FY02 Evaluations

($330K Investment)



Medical

UH-60 Aircraft• Ergonomic Solutions

• Repetitive arm/wrist motions • Adjustable pneumatic

tool set• Tool extensions &

universal joints• Battery operated

tools• Flexible screwdriver



Recommended Solutions



Ergonomics

• Illumination• Overhead lighting• Improper illumination

can cause eye strain and headaches

• Work area design• Align computer to

keyboard and operator’s sight line

• Have desk and workstation arranged at same height level

• Avoids neck and back pain

T-700 Engine



Safety & Health

• HAZMAT• Issue: Chemicals handled

without proper safeguards• Lean Recommendations:

• Verify Personal Protective Equipment is available

• Instruct operators in proper use of Alodine

• Protect workers from applied areas

• Benefit:• Reduce chance for

potential injury or health problems

UH-60 Aircraft

• John Secrest (Industrial Hygiene) was consulted (ext. 1-2746).



Lean Manufacturing

Work Area

Press

Jigs

1st Floor Rotorhead

Shop

Relocate Jigs Here

65 ft

75 ft

6 ft

CH-47 Rotor Head

• Productivity Improvements:• Time lost walking:

• Special jigs and measuring tools are kept in a cabinet at the end of the shop on both floors.

• Method Improvement Recommendation:

• Relocate special jigs cabinet next to hydraulic press

• Relocate special measuring tools cabinet to centralized location

• Benefit:• Productivity increase of ≈ 3 - 5 %



Quality

UH-60 AircraftOperation: Shimming

• Issue: Time consuming to measure and slice each shim• Process time:

8 hours to slice 22 shims

• Some shims were damaged or warped during slicing process




CCAD in-process: shim holder for slicing

• Lean Recommendations:• Pre-measured shims/

washers in assorted widths

• Requires Engineering support

• Benefits:• Reduce potential wrist

injuries• No scrapped shims • Save time ~ 8 hrs per

process



Foreign Object Damage

Training: FOD• Issue: FOD in IR Jammer Panel

• Operator uses IR Jammer Panel to sort screws

• Lean Recommendation:• FOD Training• Mechanics' Bag in which

to put FOD• Store screws, nuts, and

washers in a compartment box

• Benefits:• FOD awareness

• William Fischer, (FOD Program Specialist) was consulted. (ext. 1-1227)



Tools & Equipment

• TEES/TCAT developed and delivered a Method Improvement Matrix outlining the tools and equipment suggested for each of the evaluated shops

• Some of the suggested tooling and equipment actually purchased in two areas:• Rubber/Upholstery• UH-60 Assembly Line - AMG



Tools & Equipment

Work Center Title Analyst

Methods & Ergonomic

Improvements

Manufacture or Vendor Information

Qty Price Total

Develpmt Stage (DS) Briefed Budgeted Implemt

Stage (IS)Implemtd

(IMP)

Date Cmplt Date Y/N Date Cmplt Date Cmplt

15SAA0 Blade

Shop

T. Sandoval, J. Smith, & P.

ChhotuCordless Drill Makita Item

#DA392DWD 1 $185.00 $185.0005/02/02 05/08/02


Chhotu

Torque adjustable pneumatic

threading toolVarious Vendors

1 $200.00 $200.0005/02/02 05/08/02


ChhotuDrill Stops Click to View

harborfreight 4 $10.00 $40.0005/02/02 05/08/02


ChhotuHot Knife Click to View

Buildcenteral.com 8 $180.00 $1,440.0005/02/02 05/08/02


ChhotuScrew Out Craftsman

4 $20.00 $80.0005/02/02 05/08/02


Chhotu

Adjustable, Mobile Table Granger

1 $1,300.00 $1,300.0005/02/02 05/08/02


ChhotuClamps Various Vendors

2 $18.00 $36.0005/02/02 05/08/02


Chhotu

Metal Box with locking mechanism Various Vendors

1 $750.00 $750.0005/02/02 05/08/02


ChhotuJib Crane Various Vendors

1 $3,000.00 $3,000.0005/02/02 05/08/02


ChhotuFlexi-guard Shield Flex-bar Flexi-guard

Model #13001 1 $35.00 $35.0005/02/02 05/08/02


Chhotu

Small Torque Wrench

Grainger Item #1ARL6 1 $124.00 $124.00

05/02/02 05/08/02


Chhotu

Large Torque Wrench

Grainger Item #1ARL7 1 $135.00 $135.00

05/02/02 05/08/02


ChhotuTags (red/yellow) Various Vendors

8 $32.00 $256.0005/02/02 05/08/02

Sub Total $7,581.00

STATUS ImplementationSTATUS Methods & Ergonomic

Improvements



Implemented Suggestions

Rubber and Upholstery Shop



Fuel Cells - Before

• ISSUE: Storage Shelves

• Shelves presently in use bent, damaged, badly setup and UNSTABLE

• Pods and fuel cells can be damaged by dragging them on shelves



Fuel Cells -Method Improvement

• SOLUTIONS:

• New shelves setup (or old shelves re-done) with fuel cell/pods and present moving equipment in mind

• Palletize pods and fuel cells



Fuel Cells - After

• New shelves have been setup for fuel cells

• Removal of palletized loads can be accomplished by one worker instead of two



BENEFITS: Palletizing Pods And Fuel Cells

• Palletizing will allow one person storage and retrieval

• 50% time savings, twenty minutes per cell or pod

• Reduce damage to pods and fuel cells



BENEFITS: Palletizing Pods And Fuel Cells

• Standard pallets can be modified at CCAD

• Routing flow chart painted on pallets

• Pictures are illustrative only



Palletizing Pods And Fuel Cells

• Drawings rendered by TCAT Engineer at request of supervisor (5UFE0)



Upholstery Shop - Before

• ISSUES:• Armored seats (weigh

approximately 150 pounds)

• Must be moved twice during repair and sale

• Most workers in this shop on medical placement

• Hoists requested by H. Martinez (1/4/2000)



Upholstery Shop -Method Improvement

• SOLUTION:• Hoist for AH-64 pilot and

co-pilot’s seats

• BENEFIT:• 50% savings in time



Upholstery Shop - After

• Both solutions have been purchased, but no rigging apparatus



Rubber-Working Tools - Before

• ISSUE:• Shortage of rubber-

working tools• SOLUTIONS:

• Acquire tools• Skiving knife • Stitchers in assorted sizes

• BENEFITS:• Increased

quality/proficiency• Increase productivity

10-25%• Expanded CCAD capacity

• In process as per Al Gonzales



Rubber-Working Tools - After

• CCAD completed: Mill knives have been obtained for shop personnel

• Stitchers have not been obtained



Implemented Suggestions

UH-60 Assembly Line - AMG



AMG Assembly - Before

• ISSUE: Vent test plug supported by jack

• Safety issue: Jack is unstable, especially when pressure is applied

• Old plug was not reliable



AMG Assembly-Method Improvement

• SOLUTIONS:• CCAD completed: new

vent plug• Supervisor Dan Guerra’s

suggestion

• BENEFITS:• Eliminate the need for

jack• Time savings ~ 2.3 hr.

per process



• New vent plugs purchased by supervisor Dan Guerra

• Plug is inserted in vent opening and inflated

• Eliminates jack (safer)• Probability of passing

vent test on the first try has significantly improved

AMG Assembly - After



Potential ROI for Vent Plug

CAT 2 hrs Labor Rate Labor CostCost of

Implementation Total CostTime Savings

(Hrs.)Before

implementation of new vent plug 14.99 $ 88.19 $ 1,321.97 $ - $ 1,321.97 2.3

Projected Time Savings

After implementation of new vent plug 1.861 $ 88.19 $ 164.12 $ 25.00 $ 189.12 13.129

Actual Time Savings

Benefit/aircraft 1,132.85$

Aircrafts per year

$ Benefit per

aircraft

Total $ Benefit per

Year19 1,132.85$ 21,524.08$

UH-60 Production Section: Operation - Vent System Test

Note: FY02 Labor Rate for ROI includes overhead costs



Equipment Acquisition

• CCAD needs to concentrate efforts to acquire suggested tools and equipment• Assign ownership to purchase equipment and

tooling• Assign a budget for improvements• TEES/TCAT serves as a resource and

catalyst for change



Benefits from Evaluations

• Tangible Benefits• Increased efficiency• Increased productivity• Improved quality

• Intangible Benefits• Reduced lost work days due to injury• Reduced workers’ compensation claims• Ergonomics knowledge gained• Increased worker morale



Available Support

• TEES/TCAT pairs with trained personnel to help CCAD establish and maintain a SOLID Ergonomics Program• Dr. John F. Ayala, P.E. – depot and industrial expert• Dr. Jerome J. Congleton, C.P.E., P.E. – ergonomics expert• Research Engineers – trained in the application of ergonomics

• Training of CCAD Personnel on Basic Ergonomics Assessment tools - RULA, REBA, Strain Index, etc.

• Support Ergonomic Committee members during evaluation of shops



Intervention Program

• Medical & Ergonomic Intervention Program • Aims to reduce Workers’ Compensation claims• Worker with pain evaluated by doctor• Case referred to Ergonomic Intervention team (48 hours)• Ergonomic Intervention team administers Body Part Discomfort

Survey (BPDS)• Ergonomic Intervention team videotapes current working

conditions and analyze tape• Supervisor implements recommended changes• Periodic follow-ups are made to determine:

• Improvement• No change• Worsening



Intervention Program

• Transfer of knowledge• Teach workers basic ergonomic techniques• Develop training sessions• Assist personnel evaluating shops

• TEES/TCAT engineers have been successfully evaluating shops• Identify problems (medical, ergonomic, lean, etc)• Suggest solutions • Develop cost analysis on suggestion

• Reduction of Workers’ Compensation Claims• Increase productivity



Synergy

CCAD CCADLimited

knowledgeWMSD’s

Back injuriesCarpal Tunnel Syndrome

Worker’s Comp

Basic knowledge

Prevention of Injuries

CooperationIncreased Productivity

QualityCurrent Situation Ideal Situation

CCAD + USACHPPM + TEES/TCAT= Successful Ergonomics

Program


Texas Engineering Experiment Station

Questions & Answers



Contract Vehicles

• Aging Aircraft Commands:• U.S. Army Aviation Missile Command Omnibus 2000 (O2K)• U.S. Air Force Design and Engineering Support Program (DESP)• U.S. Navy Technology Investment Agreement (TIA)

• Other Commands:• U.S. Army Simulation, Training and Instrumentation Command Omnibus• U.S. Army Medical Research Materiel Command CAAS Contract• U.S. Air Force 311th Human Systems Wing Basic Ordering Agreement

• Other Avenues:• Grants• Broad Agency Announcement (BAA)• Program Research & Development Announcements (PRDA)• Cooperative Research & Development Agreement (CRDA)• Cooperative Agreements (CA)• Texas Qualified Information Systems Vendor (QISV)



FOR MORE INFO

Dr. John F. Ayala, P.E.210-534-7227

[email protected]

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