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Paul Soukaseum ME/IE InternAutomated Systems and Robotics A.S.Industrial and Systems Engineering B.S.University of Minnesota

• Oshkosh Corporation Classification: Unrestricted

2Paul Soukaseum 05/03/2023

What Is ME/IE?

Director: Todd RoughsedgeTeam: Vijay, Ben, Peter, Camron, Dan, Sean, Sravan, Jigs/Fixtures

• Stands for Manufacturing Engineering/Industrial Engineering• Design manufacturing jigs or fixtures• Offer production support on new and existing product• Standardize work • Study capacities and utilization• Cost justification• Improve workflow


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Internship Project

Prototype Support for Meridian• Meridian Process Improvements

Part and BOM Audit Build Sequence CI using 6 Sigma Methodology

• Meridian Fixtures/Jigs Modifying Existing Fixtures Creating New Fixtures



Observing Meridian Production

Process ImprovementBased off observations of the Meridian



Fastenal Part/BOM AuditProblem:To make sure Fastenal parts for the Meridian is stocked for production

Approach:

• Gather the all Fastenal/Aeroquip part numbers in PMPF• Compare to Meridian BOM• Find the “Missing Part”• Create BIR for BOM mistakes• Create locations for Parts Needed



Benefits from Part/BOM Audit

Improvement:• BIR created to have R&D Engineering review parts list before

giving them a location (Cost)

10,132 Total Fastenal Parts337 Bins in PMPF227 Fastenal/Aeroquip Unique Bins377 Meridian Parts in PMPF

15 Meridian Fastenal Parts w/ No Match



Hydraulic Line Build Sequencing

Problem: To simplify the hydraulic line assembly. It’s difficult and confusing.

Approach:• Create build instruction• Make it visual• Label the hydraulic lines to correspond with build

instruction• Implement Build instruction and audit the results



Value in Build Sequencing

• Improvement:• Reduction in task time (Delivery)• Simplification of task (Quality)• Easier for the production worker (Morale)


Process ImprovementMeridian improvement using 6 sigma methodology



DMAIC: Boomerang AlignmentDefine:Find the root cause of the poor fit when installing the ejector hydraulic cylinder and to correct it.

Define Non-Conforming as: “If they have to use the tap or ream out any of the holes”



DMAIC: Boomerang Alignment Measure:• The fixture is also the boomerang part• Measure parts to assure they are good

• Boomerang:# 9,8,37,35,36 = 1.8 < Cpk < 10

• Laser-cut Sidewall:Laser cut part is oversized to 0.81”Bolts are 0.75”



DMAIC: Boomerang Alignment

Analyze:• Solidworks Motion to study varianceScenario 1 P{NonConf}= 85% Scenario 2 P{NonConf}= 62%



DMAIC: Boomerang Alignment Improve:From the Analyze step, there are reasons to believe that it is the fixture or the oversize hole in the laser cut sheets

Design new fixture and use Hypothesis Testing:• Introduce new fixture & use Bernoulli distribution function

(Discrete Event) to determine the p-value. • H0: p<0.05 or <1 defect out of 20



Value in DMAIC: Process Control

Improvements and Control:• 62% reduction in the likely-hood of non-conforming alignment

(Quality/Delivery)• Fixture is lighter (Morale)• Error proofing for Scenario 1, lowers risk of 85% Non-Con (Quality) • Production are not complaining about bad fit (Morale)


Fixture Design and BuildBased off the manufacturing needs of the Meridian



Fixture Improvement ProcessProduction needs a solution to a problem

Collect Input from Shop and Cross Functional team

Validate Loading Sequence

Validate Clamping Plan vs Actual Jig

Develop Concept for Cross Functional Team Approval

Detail Design, Drawings and Part Order

Build and System Integration, Update Work Instruction

Setup the Jig to Nominal and Build Part for Quality Validation



Requirement AnalysisAnalysis:• Problem Statements• Needs/Functions• Requirements to Functions• Load Seq. and Clamping Plan• Designs/Revisions to Design

My Designs:• Tower 1 Adjustable End stop• Winnebago Roof Fixture

Modification• Riceville Rotating Weld Fixture

Foot Pedal• Hydraulic Valve Lifting Device

http://www.solidworks.com/



Winnebago Fixture Upgrade

Problem Statement:The contract manufacturer contacted us with an opportunity to improve the roof fixture.

Revision to Design:• 3 Panel End-Stops• 10 Extended bracing• 2 Clamps and brackets• 4 Rack and pinion covers


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Value in Winnebago Upgrade

Paul Soukaseum

Improvement:• Contract manufacturer issues are addressed (Morale/Delivery)• Additional end stops and clamping hold parts securely (Quality)

x10 x3

x2x4



Tower 1 End Stop Upgrade

Problem Statement:Tower 1 needed end-stops for the Meridian and I saw an opportunity to consolidate the end-stops and lower variability.

Revision to Design:• 1.5” Wider roller• Threaded end with locker• Extra offset hole• Longer Pins• 4X for all sides



Tower 1 End Stop Upgrade

Improvements:• 42.2% Reduction in Setup Time (Delivery)

– Increase capacity – Increase production efficiency

• Setup Process Simplification (Quality)• Additional Error proofing (Quality)• Adjustability for Yearly Calibration (Quality)



Riceville Foot Pedal Upgrade

Problem Statement:The foot pedal could be activated accidently, which is a safety issue.

Revision to Design:• Remove current pedal• New pedal to the outside of active

working area• Add a drive shaft• 2X for similar fixture

SAFETY ISSUE



Benefit from Foot Pedal Upgrade

Improvement:• 98.2% Reduction in Risk Priority Number in the function (Safety)

Oshkosh PFMEA



Hydraulic Valve Lifting Device

Problem Statement:Operator must lift and manage the 175lb Meridian hydraulic valve, OSHA requires a lifting device

Design• Pivot bearing to rotate valve• 20mm threaded attachment• Safe for lifting 175lb valve• Test with a 5x safety factor

175lbHydraulic Valve



Value in Valve Lifting Device

Improvements:• Dennis uses it and Safety approves (Morale)• Reduction in physical exertion (Safety) • Safety hazard prevention (Safety)• Tested “Homemade Tool” (Safety)


Take away



The Take AwayWhat I learned:• Process of new product launch from the manufacturing perspective• Hands on person• School of common sense• More knowledge about all the roles of ME/IE• Application from what I’ve learned in school• More about Oshkosh and McNeilus• How to ride a long board

McNeilus Benefits• Improve areas of: Safety, Quality, Delivery, Cost, Morale


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The Take Away

Future Goals:• Finish last year of schooling • Get more involved with Automation/Engineering• Get more Involved with Process Improvement (Stats/DFSS)

Overall:• Great people (interns and employees)• Great experience

Paul Soukaseum



Acknowledgements:

• Director/Mentor: Todd Roughsedge • Everyone in ME/IE, Vijayakumar Kittuswamy, Peter Howard and

Ben Horejsi• Jigs and Fixtures: Jim, Brian and Dave• Quality Team• PFMEA: Jim Luraghi• Safety: Ross Coberly • Materials: Justin Carlson• Production: Seng and Eli


Presentation Over