Department

Industrial and Manufacturing Engineering Department

Degree Name

BS in Manufacturing Engineering

Date

6-2010

Advisor(s)

Daniel Waldorf

Abstract

Alcon’s Laser Clean Room fosters inefficient production practices, is outdated for its current process, and lacking in clear process/product flow. A facility re-design is applied to bring order, efficiency, and optimize flow in the laser production lines.

Deliverables include a new layout that decreases product travel distances and increases productivity as well as an implementation plan and cost/savings analysis. Major design decisions include downsizing the clean room, sorting to find waste and establishing clear process/product flows. The design was implemented within three weeks and results yield 29% reduction of product travel distance, 10.4 hrs/day saved from eliminated gowning time and 23% increase in productivity. Cost/savings analysis estimate a payback period of three months and then a yearly savings of roughly $135,396.

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