Date

6-2010

Degree Name

BS in Manufacturing Engineering

Department

Industrial and Manufacturing Engineering Department

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Alcon’s Laser Clean Room fosters inefficient production practices, is outdated for its current process, and lacking in clear process/product flow.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.