Intern Presentation 2015: Agilis, Pacel, and Reflexion ProjectsCourtney Paulson

Introduction Courtney Paulson University of Wisconsin-

Madison, Budapest University of Technology and Economics

Industrial and Systems Engineering, Six-Sigma Green Belt Certificate

June 2016 Manufacturing Engineer Intern

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Agilis: Window Cutter and Hub Alignment Fixture Scrap rate: 15%, planarity one of the highest

Mark at pull wire position to aid processes in accurate planarity outputs

Insufficient mark: Process flow chart Ink Study: Find best ink methodology

Testing ink capsules of various dilutions Capsule dry time, percent fallout, part dry time

Solution Slide fixture to cover ink capsule in idle position

Impact Consecutive markings increased Removed need for Sharpies in process Improved accuracy with cameras Changed scrap range for planarity Completion increased yields

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Agilis: Window Cutter and Hub Alignment Fixture Manufacturing Procedure (MP) for

Window Cutter and Hub Alignment Fixture

Updated current MP, added the option of using new fixture Operator reference photos for fixture

steps and fallout conditions Ink preparation methodology Communicated and walked through MP

with operators and engineers for constructive criticism

Results Removed sanding step MP currently in use Reduced number of operators and

fixtures from 2 to 14

Pacel: Wire Stripper and Shoulder Forming Process PQ failed: due to electrode length

variation Reduce variation by targeting the source

Fishbone diagram of all sources of variation

Shoulder forming: pressure levels Tested and measured shafts at different PSI,

process was capable Dissected failed PQ parts

Correlation between electrode spacing length, and the length from tip to core wire insulation

5-factor DOE: distinguish variation factor Angle of cut Homing Location on trigger Insertion speed Pressure on trigger5

Pacel: Wire Stripper and Shoulder Forming Process Results

Speed of entry and location of shaft against trigger

More length tests based on DOE CAD designed track

Solution and Impact Track did not work

Was not adjustable to different French sizes

Didn’t change insertion speed In the process of designing a

measurement die Spot check wire strip length before

movement down the line

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Reflexion Catheters: Component Scrap Reduction Target source of Material Usage Variance (MUV) Process flow diagram: Potential sources of MUV

Results: Kitting: incomplete kits going to production line Material Consumption: over inspection, unnecessary scrapping Material Reconciliation: making assumptions for unreturned items SAP: changes made to account for incomplete kits

Solution and Impact: Smaller adjustments to each process Work in process

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Conclusion New Learnings:

FMEA: failure mode and effects analysis Process flow diagrams for all projects Agilis and Pacel part testing and measurements Analysis of data

DOE: design of experiment where variation is present Pacel 5-factor DOE

Manufacturing Procedure knowledge New perspective on the medical device industry

Goals: Graduate in the spring of 2016 and start career path shortly

after Start a career in the medical device industry (SJM? )

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Thank you!

Questions?

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