Cartoon Engineering, also referred to as a mock-up, despite being associated with a TV channel known from cartoons, is one of the many well-known tools used in processes improvement.
The process of designing machines and production lines takes place in the office. It is there that a constructor or a team of specialists, using computers and special software, implements his or the client’s vision. During this process, we are not able to predict all the problems that we will face during the line or machine launch.
Among the problems that we can meet will be the broadly understood optimization of the operator’s working position, the lack of ergonomics, the distribution of coverage zones, as well as a number of technical solutions that should be used in the device so that the operation is performed safely, efficiently and in accordance with the customer’s expectations.
In order to eliminate these problems, we can use a number of modern methods using the potential of virtual reality or a tool called Cartoon Engineering. We can then easily translate into a real concept of a new line or machine. The goal is to use the title cardboard. From there the interdisciplinary team under the leadership of the leader of the entire project builds a position or a production line.
Cartoon Engineering project should involve representatives of various departments directly related to production. That is why it is so important that the project involves a machine operator, a representative of the Lean, EHS, technical, quality and maintenance departments. Additionally, a representative of the supplier may participate in the project, whose task will be to implement new solutions.
How to start the implementation?
The first phase of Cartoon Engineering is the kick-off meeting where the Project Leader presents the main assumptions of the new launch / modification. It also discusses all positions and processes, taking into account the forecasted production volume as well as the number of potential changeovers. During this phase of the project, the team gets to know the line layout, has access to DFMEA and the client’s requirements regarding e.g. packaging or control standards.
The next phase of the project is work in the area where the workstation or the entire line is built by a team on a 1: 1 scale. It is best if the work takes place at the destination or at the supplier. It is advisable that the area where the Cartoon Engineering project takes place should be adequate to the layout assumptions of the designed line.
The area used should take into account assumptions about the direction of material flow. In addition, we take into account the organization around and directly on the line in terms of the arrangement of components, tools and documentation.
Constructed positions are equipped with all details. We do not ignore safety switches, safety curtains, cycle triggers, electrical cabinets, zones for products between workstations (buffers), final products, component feeders and finally panels / monitors that enable the control / monitoring of the machine.
Thanks to the stations built in this way, the team participating in the Cartoon Engineering project conducts a production simulation using real components.
The purpose of the simulation is:
- cycle time measurement
- observation of activities
- the analysis is work ergonomics
- loss identification (MUDA)
- verification of threats in terms of operator safety on the machine
- checking the potential risk for the quality of products
During the simulation, the Maintenance representative analyzes tools, panel positions and electrical cabinets. It is important from the point of their availability during a possible failure or preventive actions.
All suggestions and anomalies must be registered. Then, in the team, we develop an action plan, define those responsible for their implementation and estimate the time of their closure. The Cartoon Engineering team should continue meetings after the end of the working phase of the project. The aim is to verify the planned activities and their effectiveness after their implementation.
Cartoon Engineering and benefits for the company
Cartoon Engineering is a very simple tool to use. At the same time, it allows you to make very significant changes to the concept of the machine or the organization of the work of the entire line at an early stage of the project. In addition, with the involvement of the entire team, it allows you to avoid mistakes and faults.
What exactly are we talking about? About the need to modify lines, machines or tools when the stations are already delivered to the client.
Ryszard Budniok
