DESIGN OF A DASHBOARD FOR QUALITY INDICATORS

MANAGEMENT OF A BALSA KITS PROCESS IN A WOOD

COMPOUNDS COMPANY

Aldo Mero & Karen Velastegui

Industrial Engineering
Project Advisor: Kleber Barcia, PhD
July 17, 2020
AGENDA

PROJECT CHAPTER

DESIGN PLAN

NEXT STEPS
 SUMMARY
OPPORTUNITY STATEMENT PRINCIPAL DESIGN REQUIREMENTS
Design of a dashboard for quality indicators
management in a production process of
flexible balsa wood kits, to generate quality Generate process status reports at anytime
reports using actual process information.
Detect points out of statistical control in the
process

Convert the collected data from QC points to

DASHBOARD CONSTRAINS statistical controls.

Compatibility with the Provide access to a helping tool.

operating system currently
used by the company's tablets.
Multidevice compatibility.
Compatibility with the
database systems used by the Show specifications product compliance
company. percentage, using indicators.
 CURRENT SITUATION
Reception of
Processing Balsa Line (Panel
START Flexible Wood Type merging)
Sparcap Cutting
Panels

·
Cutting

Hand-made
Fillet Cutting
pieces

PACKAGING

Stock Warehouse Shipping

Up to 3% of orders are Sampling frequency

High times to create
rejected per month. Policy is not properly Manual Inputs -> High
reports (at least an followed. (Sometimes Risk of Error
Rejection cost is $2041
hour and a half) more than 30min)
per m3.
BUSSINESS MODEL CANVAS

Quality Process Reduction of time to Quality Auditor

Monitoring generate reports Automated services
Quality Department

Quality Process Data monitoring on

Reporting anytime Personal assistance Quality Manager
Production
Department Possibility to identify
possible failures in the Production
process Manager
Parameter Measures Company Network
of the process
Project & IT Production rework
Department and scrap costs Projects Head
PGS Workers Microsoft Office
reduction in the long
Network
term
Company Database

Monetary income increases in production due to

Office 365 licenses Power BI licenses Tablets the decrease in non-conforming product
investment
 DESIGN PROPOSAL
Reception of
Processing Balsa Line (Panel
START Flexible Wood Type merging)
Sparcap Cutting
Panels

·
Cutting

Hand-made
Fillet Cutting
pieces

PACKAGING

Implement the usage of tablets

Stock Warehouse Shipping
in the process

Order rejection rate Quality sampling There must not be

Create quality reports policy is more parameter record
should be lowered at
with just one-click- controlled errors.
least 60%
AGENDA

PROJECT CHAPTER

DESIGN PLAN

NEXT STEPS
DESIGN PLAN

Prototype Company
Parameter Database
Design and
Analysis Conection
Validation
TOOLS: TOOLS: TOOLS:
• Quality Statistical Tools • Microsoft Excel (Macros) • Microsoft Excel (Macros)
• I-M Control Chart • Power Automate • Power Automate
• Microsoft Excel (Macros) • Power BI • Power BI
• Power Automate • Go ToMeeting • Go ToMeeting
• Go ToMeeting
RESPONSIBLES: RESPONSIBLES:
RESPONSIBLES: • Project Leaders • Project Leaders
• Project Leaders • Quality Manager • IT Manager
• Quality Manager • IT Manager • IT Analyst
• Projects Manager • Projects Manager
FINISHED: 20/08/2020
FINISHED: 08/08/2020 FINISHED: 13/08/2020
VALIDATION: 21/08/2020
VALIDATION: 11/08/2020 VALIDATION: 17/08/2020
DESIGN DEVELOPMENT
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation

CONTROL CHART SELECTION AND INDICATORS DEFINITION

ABERRANT DATA IDENTIFICATION
expectedmeasure−actualmeasure
 

 𝑛𝑜𝑛𝑐𝑜𝑛𝑓𝑜𝑟𝑚𝑖𝑛𝑔 𝑝𝑖𝑒𝑐𝑒 𝑠𝑡
𝑡𝑜𝑡𝑎𝑙 𝑝𝑖𝑒𝑐𝑒 𝑠 𝑡
DESIGN DEVELOPMENT
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation

PGS Quality Control

PARAMETER SEGMENTATION

Line Feeding Balsa Line Sparcap Cutting 11/18 Cutting Fillet Cutting Handmade pieces

· Left Lenght
Control Chart

· Initial width · tart Width

Group 1

· Lenght
· Left Chamfro · Right Lenght
· Thickness · End width · End Width
· Degree
· Right Chamfro · Left Chamfro
· Moisture · Left length · Left Lenght
· First Slot
· Transition · Right Chamfro
Distance
· Right Lenght · Right Lenght
· Transition
Group 2

· Homogeneity
Pie Chart

· Opening
· V Cut
between panels · Slot number
· Bacth · Angle · Scrim Position
· Angle
· Fabric Status · Distance
between slots

· Slot Width

· Unslotted Depth
 DESIGN DEVELOPMENT – PROTOTYPE DESIGN
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation

• MICROSOFT EXCEL (MACROS) + POWER BI

 DESIGN DEVELOPMENT – PROTOTYPE DESIGN
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation

• MICROSOFT EXCEL (MACROS) + POWER BI

 DESIGN DEVELOPMENT – PROTOTYPE DESIGN
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation

• POWER AUTOMATE + POWER BI

DESIGN DEVELOPMENT - VALIDATION
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation
DESIGN DEVELOPMENT
Prototype Company
Parameter Database
Design and
Analysis Conection
Validation
IMPLEMENTATION & CONTROL PLAN
IMPLEMENTATION PLAN
DASHBOARD
WORK SAMPLING
OPERATION IMPLEMENTATION + VALIDATION OF
WORKERS TRAINING MANAGE TRAINING DATA COLLECTION FOR QUALITY RESULTS
AUDITOR
TOOL
USER: QC Workers USER: Quality and USER: QC Workers, USER: Quality Auditor RESPONSIBLES:
Production Manager Quality and Project Leaders,
Production Manager Quality and
Production Manager
TOOLS: Personal TOOLS: Personal TOOLS: Personal TOOLS: Time Study
training training training, work
sampling, fatigue
analysis
TRAINING DATE: TRAINING DATE: TRIAL PERIOD: 27/08 FINISH DATE: FINISH DATE:
26/08/2020 26/08/2020 – 03/09/2020 27/08/2020 04/09/2020

CONTROL PLAN
TRIAL PERIOD: 04/04/2020 – 09/09/2020
 FINANCIAL ANALYSIS
ANNUAL CASH FLOW SCHEME (MICROSOFT EXCEL (MACROS) + POWER BI)
YEARS 0 1 2 3 4 5 TMAR 18%
Initial investment in hardware (tablets + optical pencil) -$7.000,00
Expected savings / year $353.734,69 $360.809,39 $368.025,57 $375.386,08 $382.893,81
Hardware replacement cost (computers) -$1.425,00
AOC - Computer / Tablet Maintenance -$2.640,00 -$2.640,00 -$2.640,00 -$2.640,00 -$2.640,00 Considerations:
AOC - Offi ce 365 + BI Annual License -$360,00 -$360,00 -$360,00 -$360,00 -$360,00 • 3 computers and a
Depreciation (Fixed assets - tablets) -$1.176,00 -$1.234,80 -$1.296,54 -$1.361,37 -$1.429,44 -$1.500,91
Depreciation (Fixed Assets - Computers) -$383,33 -$402,50 -$422,62 tablet that currently
Amortization (Offi ce 365 + BI License) $360,00 $360,00 $360,00 $360,00 $360,00 exist
Equipment salvage value $275,00 • Power BI license
Cost of rejected orders / year -$387.247,91 -$367.885,51 -$349.491,24 -$332.016,68 -$315.415,84
AOC - physical quality reports -$55,00 -$55,00 -$55,00 -$55,00 -$55,00
purchased
Depreciation (Fixed assets - tablets) $1.176,00 $1.234,80 $1.296,54 $1.361,37 $1.429,44 $1.500,91 • 7 new tablets are
Depreciation (Fixed Assets - Computers) $383,33 $402,50 $422,62 purchased for operators
Cash Flow -$7.000,00 -$36.208,22 -$9.771,13 $14.689,33 $40.674,41 $64.782,96
VAN $13.534,61
TIR 28%

TIR TMAR
As the TIR is higher than the TMAR, the project is financially
viable. 28% 18%
 FINANCIAL ANALYSIS
CONSIDERATIONS:

Tablet ET5x series

Is used for:
• Work order management
• Asset tracking
• Direct store delivery
• Inventory management
• Mobile payment

A Windows tablet is chosen as Macros only work on this type of

tablet
 FINANCIAL ANALYSIS
ANNUAL CASH FLOW SCHEME (POWER AUTOMATE + POWER BI)
YEARS 0 1 2 3 4 5
Initial investment in hardware (tablets + optical pencil) -$3.500,00
TMAR 18%
Expected savings / year $353.734,69 $360.809,39 $368.025,57 $375.386,08 $382.893,81
Hardware replacement cost (computers) -$1.425,00 Considerations:
AOC - Computer / Tablet Maintenance -$2.640,00 -$2.640,00 -$2.640,00 -$2.640,00 -$2.640,00
• 3 computers and a
AOC - Offi ce 365 + BI Annual License + Power Automate -$540,00 -$540,00 -$540,00 -$540,00 -$540,00
Depreciation (Fixed assets - tablets) -$616,00 -$646,80 -$679,14 -$713,10 -$748,75 -$786,19 tablet that currently
Depreciation (Fixed Assets - Computers) -$383,33 -$402,50 -$422,62 exist
Amortization (Offi ce 365 + BI License + Power Automate) $540,00 $540,00 $540,00 $540,00 $540,00 • Power BI license
Equipment salvage value $275,00
Cost of rejected orders / year -$387.247,91 -$367.885,51 -$349.491,24 -$332.016,68 -$315.415,84
purchased
AOC - physical quality reports -$55,00 -$55,00 -$55,00 -$55,00 -$55,00 • Power Automated
Depreciation (Fixed assets - tablets) $616,00 $646,80 $679,14 $713,10 $748,75 $786,19 license purchased
Depreciation (Fixed Assets - Computers) $383,33 $402,50 $422,62 • 7 new tablets are
Cash Flow -$3.500,00 -$36.208,22 -$9.771,13 $14.689,33 $40.674,41 $64.782,96
VAN $17.034,61 purchased for operators
TIR 31%

TIR TMAR
As the TIR is higher than the TMAR, the project is financially
viable. 31% 18%
 FINANCIAL ANALYSIS
CONSIDERATIONS:

An Android tablet is chosen as the Power

Automate form can work on any type of tablet
FINANCIAL ANALYSIS

MACROS + POWER POWER AUTOMATE

BI + POWER BI
VAN $13.534,61 $17.034,61
TIR 28% 31%

You can see that the best option would be Power Automate +
Power BI
SENSITIVITY ANALYSIS
Microsoft Excel Microsoft Office Power BI Power Automate
(Macros) Excel - Online
Multi-device
- -
Flexibility to
unexpected changes
(Easy to program)
Allows working with
intranet
Can be updated in
real time
Allows you to create
statistical control -
charts
Provide user support
Allows you to
manage indicators -
SENSITIVITY ANALYSIS
Power Automate + Power BI

Multi-device
Flexibility to unexpected changes (Easy to
program)

Allows working with intranet

Can be updated in real time

Allows you to create statistical control charts

Provide user support

Allows you to manage indicators
AGENDA

PROJECT CHAPTER

DESIGN PLAN

NEXT STEPS
NEXT STEPS

• Implementation
• Prototype and Validation results