Q2 Overview

Quarter 2

In Quarter 2, we blended hands-on experience with essential industry concepts to deepen our understanding of modern manufacturing. We kicked off the quarter by learning directly with understanding and Lean manufacturing, then we hopped into a CNC lathe, where we learned precision machining techniques and gained practical experience programming and operating the equipment. Our journey continued into the realm of robotics, exploring automation and smart systems integration that are transforming production processes. Finally, our study of lean manufacturing provided us with valuable insights into streamlining operations, reducing waste, and enhancing efficiency. Together, these modules have

Lean Manufacturing & Efficiency Improvements

Intro to Lean

Lean methodology aims to eliminate waste and enhance productivity, with two primary approaches: people-centric, which prioritizes employee well-being and development, and profit-centric, which focuses on maximizing financial gains. Lean principles play a vital role in automation and Industry 4.0 by optimizing and streamlining processes for greater efficiency.

The 3 Ms of Lean

3 M’s of Lean

• Muda (Waste): Eliminating unnecessary actions.

• Muri (Overburden): Reducing excessive strain on workers/machines.

• Mura (Unbalanced Workload): Preventing inconsistencies in production.

The three M’s of Lean—Muda, Muri, and Mura—address key inefficiencies in production. Muda focuses on eliminating waste by removing unnecessary actions, Muri reduces overburden to prevent excessive strain on workers and machines, and Mura minimizes inconsistencies in workload distribution to ensure a balanced production process.

House of Lean

• Foundation: People, purpose, and stability.

• Walls: Quality and production.

• Roof: Company goals.

The House of Lean represents a structured approach to Lean methodology, emphasizing stability and continuous improvement. Its foundation consists of people, purpose, and stability, ensuring a strong base for sustainable growth. The walls represent quality and production, which uphold efficiency and reliability in processes. At the top, the roof symbolizes company goals, aligning all Lean efforts with the organization’s long-term vision and success.

Kaizen

Kaizen is a Japanese term meaning "continuous improvement."

Kaizen, a key principle of Lean, emphasizes small, incremental improvements to enhance productivity and efficiency. By continuously refining processes and eliminating waste, organizations can achieve sustained growth and long-term success.

Personal Applications of Lean

Workplace efficiency focuses on reducing waste and optimizing productivity through strategic organization and process improvements. On the CNC shop floor, everybody ensures that the tools needed for usual operations are positioned for easy access to minimize motion waste.

In CAD design, careful checking of specifications prevents defects and saves time.

Organizing desks follows the 5S methodology—Sort, Set, Shine, Standardize, and Sustain—ensuring a clean and efficient workspace.

Additionally, when we wait on something, time waste is minimized by using downtime productively, such as designing in CAD.

Trash Bin- Motion waste

What Bugs Me: I used to get frustrated by having to get up, walk to the kitchen, and throw away water bottles. It broke my focus and wasted time in the middle of tasks.
Waste Identified:
- Motion: The unnecessary movement of having to walk all the way to the kitchen just to throw something away.

Solution Implemented

Action Taken: To solve this, I placed a small trash can right next to my desk. No more trips to the kitchen every time I needed to throw something away.

Results

Efficiency Gains:
- I saved time and energy by cutting out those extra steps.
- It reduced interruptions to my focus, allowing me to stay in the zone.
Lean Principle: By addressing excessive motion (one of the 7 Lean Wastes), this small change made my workspace more functional and streamlined my daily routine.

Getting Medicine- Motion waste

When I had pneumonia, I realized how exhausting even small tasks could be. I used to leave my bed to get medicine from the kitchen, but every time, it felt like a huge effort. So, I started keeping the medicine right next to me on the nightstand. It wasn’t much, but having it within arm's reach meant I didn’t have to waste energy walking across the room. It was a simple change, but it helped me avoid unnecessary movement when I was already feeling drained.

Cooking Too Much- Overproduction

When cooking, I often found that my eyes were hungrier than my stomach, and I ended up preparing more food than I actually needed. Once I realized this, especially with the help of the diet I was following, I understood that I didn’t need as much food to feel full and energized throughout the day. To tackle this overproduction issue, I decided to cook smaller portions. This not only minimized food waste but also helped me be more mindful of what I was consuming, making my meals both more efficient and satisfying.

CNC Machining - OverProcessing

When I worked on my CNC 3-Axis Mill challenge, towards the end, I considered adding another facing pass after I’d already faced the part at the beginning. However, I quickly realized this was a clear example of over-processing. Since the part had already been faced, doing it again at the end wouldn’t improve the finish—it would likely stay the same. More importantly, it wouldn’t add any value to the part, making it a complete waste of time and resources. To fix this, I decided to skip the additional facing pass, made the initial face from the beginning take more material off , and the part came out perfectly, and in a timely manner. This decision helped streamline the process and avoided unnecessary work.

2 Second Improvement - Motion Waste

When 3D modeling with specifications, I often found myself constantly looking back and forth between the design and the requirement sheet. This back-and-forth motion was time-consuming and disrupted my flow. To reduce this motion waste, I decided to write the key specifications down on a notepad on my computer and place it on my second monitor. Now, I just glance to the right instead of searching for the paper, saving time and staying focused on the task. This small 2-second improvement made a noticeable difference in streamlining my workflow.

Desk Cleaning- Inventory Waste

For my 2-second fix, I decided to organize the mess in my workspace to reduce unnecessary inventory waste.

How:

Preparation:
I designated a temporary space, like the ground or another desk, to place items from my desk. I also gathered cleaning supplies, such as wipes and cloths, and kept them within easy reach.

Clearing the Desk:
I picked up each item one by one, placing them in the temporary space. I checked drawers and under the desk for stray items.

Wiping down the Desk Surface:
I wiped down the entire surface with a cleaning wipe, making sure to clean areas that collect dust or crumbs. I used a cloth to dry and buff the surface, removing any residue.

Assessing and Organizing:
I reviewed the items I moved off the desk to decide which ones I truly need. I grouped them into categories like office supplies, personal items, or decorations.

Returning Essentials to the Desk:
I returned only the items I need daily—such as my calendars, meds, and wet wipes—back to the desk in an organized, logical way.

Storing Non-Essentials:
I identified non-essential items, like the masks I tossed on the desk after camping, and returned them to their proper place, such as my wardrobe.

Final Touches:
I assessed the newly organized desk, making small adjustments for both functionality and visual appeal. I also threw away any trash or clutter that accumulated during the process.

Maintenance Plan:
I set a mental reminder (or a physical cue) to repeat this process regularly, keeping my desk clutter-free. I also wrote a list and hung it by my desk to remind me to tidy up every time I sit down, ensuring my workspace remains efficient and clean.

Airplane Boarding

Airplane Boarding – Future State

A common problem passengers face during boarding is the excessively long process, particularly for those with economy seats, which make up the majority of the plane. As passengers slowly make their way to their seats and stow their luggage, congestion in the aisles causes significant delays. Even after everyone is seated, additional time is wasted as the plane maneuvers and tries to back up to the runway for takeoff, further impacting overall efficiency.

Scope:

Start: Passengers begin boarding from the rear of the plane.
End: Everyone is seated and luggage is stowed quicker.

Proposal 1: Optimized Boarding Process

Boarding Order: Passengers with window seats board first, followed by middle seats, then aisle seats. This order reduces congestion and smooths the flow.
Carry-On Check: Luggage size pre-verification before boarding ensures faster boarding.
SMED Focus: Streamline each boarding group to 60 seconds (approximately 10-15 passengers).

Metrics:

Boarding time per group: 60 seconds.
Efficiency improvement: +30%.
Carry-on check time: <5 seconds.

Proposal 2: Dual-Gate Boarding & Aircraft Modifications

Dual Boarding Bridges: Front and rear boarding to improve flow and reduce wait times.
Visual Tools: Digital signage and color-coded boarding passes help direct passengers more efficiently.
SMED Focus: 60-second boarding per group, with boarding from both ends of the aircraft.

Metrics:

Boarding time per group: 60 seconds.
Flight boarding time reduced by: 50-60%.
Turnaround time improved by: 25%.
Higher ROI: Through increased flight efficiency and reduced boarding times.

Challenges & Solutions:

Aircraft Redesign Resistance: Justify the need with an improved ROI.
Passenger Awareness: Clear communication through apps and signage to guide passengers through the process.

Conclusion

Lean principles can optimize productivity and reduce waste in industries like aviation.
Small, efficient improvements can lead to significant time and cost savings.
Real-world Lean applications demonstrate its effectiveness in both manufacturing and large-scale operations.
Future innovations, such as optimized airplane boarding, can substantially enhance operational efficiency in the airline industry.

Airplane Drawing (Before/After)

The solution to boarding congestion at airports could be to board from the back of the plane. Priority passengers (ORANGE) would board first, followed by semi-priority passengers (YELLOW), eliminating bottlenecks. Finally, economy passengers (GREEN) can board smoothly and quickly, allowing them to stow their luggage at their own pace without rushing.

Estimation Process

Using ChatGPT, I discovered that "most planes will start boarding 30 to 45 minutes before departure" when boarding from front to back. The math checks out because I took 30 minutes and divided it by the number of seats (24), which gives 1.25 minutes. This means, on average, it takes 1.25 minutes per person to get seated.

With my proposed improvement—boarding from back to front—I found, with the help of ChatGPT, that this method is 50% faster. Each person would take approximately 45 seconds to get seated, cutting the total boarding time down to just 18 minutes. I calculated this by multiplying 45 seconds by 24 seats (giving 1,080 seconds), then dividing by 60 to convert it to minutes, which equals 18 minutes.

Source for the quote: TravelPro Blog

Value Added/ No Value Added

Value Added:

Faster and More Organized Boarding: Boarding from back to front allows passengers to go directly to their assigned seats, reducing confusion and minimizing time spent in the aisle.
Less Pressure for Luggage Stowing: Passengers have more time to stow their luggage without feeling rushed, leading to a more relaxed and efficient boarding process.
Unobstructed Aisles: Since passengers aren’t waiting in the aisle for others to get seated, there will be fewer blockages, allowing for smoother movement throughout the cabin (unless someone is running late).

No Value Added:

Waiting to Board: The only non-value-added time is the waiting period before boarding begins. However, this can be minimized through better boarding efficiency and clear communication to passengers, reducing unnecessary waiting and streamlining the entire process.
Long Lines at Boarding Gates: Passengers waiting in long lines to board create unnecessary delays and stress. While waiting for their boarding group, time is being spent without contributing to the process of getting them to their seat.

Uneveness/Imbalances

Uneven Distribution of Luggage in Stow Areas: Passengers may place their luggage unevenly in overhead compartments, causing some areas to become overcrowded while others remain underutilized, leading to delays and wasted time.

Travelers in Groups Cause Traffic Jams: Groups traveling together may block aisles as they settle in, causing congestion and delays in getting others to their seats. Their slower pace of boarding can impact the overall flow.

Late Boarders: Late passengers can create imbalances by rushing through the boarding process, causing disruptions and holding up the flow of others. This can lead to further delays and prevent the process from running smoothly.

Possible Improvements

Split Boarding into Smaller Groups: Instead of boarding large sections at once, divide passengers into smaller groups based on their seat location (e.g., rows 25-35, rows 10-15). This can help avoid overcrowding in the aisles and streamline the boarding process.

Call Passengers Based on Seat Type: Board passengers based on their seat assignments—starting with those in window seats, followed by middle seats, and then aisle seats. This reduces congestion and allows passengers to settle in without blocking the aisle.

Incentivize Checking Larger Carry-On Bags: Encourage passengers to check larger carry-on bags by offering incentives or discounts. This can prevent overcrowding in the overhead stow areas and make boarding smoother and faster for everyone.

Takeaways

Impact of Process Improvements: Even small changes can lead to significant improvements in efficiency, demonstrating that incremental adjustments can have a large impact on overall performance.

Value of Level Loading: Evenly distributing boarding groups helps cut down on congestion and wasted time, ensuring a smoother and more organized process for both passengers and airline staff.

CNC Lathe

This section highlights my work with CNC lathe machining, specifically using the HAAS ST-10Y machine. The process involves careful loading and unloading of tools, followed by aligning the tool holder with a coaxial dial indicator to ensure it is properly centered on the spindle for precise cuts. I also dialed the tool on both the X and Z axes to guarantee accuracy. Along the way, I encountered some mistakes, but I was able to identify and correct them, refining my technique for better results.

Tool Changing

To remove a tool on the HAAS ST-10Y, we first make the adjacent tool accessible, such as bringing tool 3 into position if removing tool 5. We then unscrew the two securing screws and gently tap the tool out with a mallet, as it's held by a wedge. Next, the coolant sprayer is removed by unscrewing the screws and lifting it off the magnet. After removing the tool, the replacement is loaded, refining the tool-changing process. We handle both axial and co-axial tools with precision during this process.

What are Axial, Co-Axial, and Radial Tools?

Axial Tools cut along the spindle’s axis for tasks like turning, facing, or drilling, focusing on the length of the part.

Co-Axial Tools work with multiple axes simultaneously, allowing for more complex operations like angled milling or drilling.

Radial Tools cut along the radius of the workpiece, typically used for side milling or profiling the outer surfaces

Dialing in X Axis To Spindle Center Line

To dial in the tool on the X-axis, we placed a .005 thick metal piece between the tool and the part. We carefully adjusted the position until the tool was slightly pinched between the metal piece and the part, allowing just a small amount of movement. Once aligned, we input the offset into our workspace and subtracted the part's radius to ensure the tool was accurately positioned for the machining process.

Dialing Z Axis

To dial in the Z-axis, a 123 block was used, positioned against the chuck wall with the tool slowly creeping toward it. Care was taken to avoid crashing the block into the tool insert, which caused a chipped insert on the first attempt. After replacing it, the tool was adjusted for light contact with the block. The offset was then entered, and 3 inches were subtracted to accurately position the chuck in the Z-axis.

Dialing Tool Holder To Spindle Center Line

We used a co-axial dial indicator to align the tool holder with the spindle centerline. This step is crucial for ensuring that the tool is perfectly aligned during operations like center boring, preventing misalignment that could affect cut accuracy. The dial indicator allows for precise adjustments, minimizing any deviation.

Through repeated practice and fine-tuning, I achieved a clearance of under a micron—well within half a tenth—demonstrating a high level of precision and consistency. This attention to detail ensures that each machining operation is executed accurately, contributing to the overall quality of the final part.

Changing Tool Insert

After the 123 block crashed into the tool insert during my first attempt, I had to replace the insert. Instead of installing a new one, I unscrewed the insert and flipped it to another side, as it’s designed to cut on all sides. Once flipped, I carefully screwed it back into place, allowing me to proceed with the setup.

Modeling Part

Initially, I had difficulty deciding on the design for my part but eventually chose a dumbbell shape. I modeled half of the part and then used the revolve tool to create a 3D object, ensuring symmetry and precision as the design developed. I then Extrude-cut a hole for the center bore.

Defining Stock XYZ in CAD

I designed a part with a .900 diameter using 1-inch stock to allow for facing and a smoother finish. Adjustments were made to accommodate the CNC lathe’s different XYZ axes, including orienting the Z-axis outwards and aligning the XY axes to ensure proper machining alignment.

Simulating Operations

To simulate cutting the part, I started with a face cut and a center bore. I attempted a profile rough, but the cut was too aggressive. After discovering the "multiple passes" option to reduce tool load with smaller cuts, I adjusted the setting and continued shaping the handle’s profile. I used Tool 4 to make the end more spherical, refining the spheres for precision. As I approached the final shape, I used a grooving tool for finer cuts. I then removed more stock to create space for the parting tool, which was used to cleanly separate the part from the chuck. Finally, I parted off the dumbbell.

The Blueprint

In this blueprint, I referenced everything from a single datum, which was located on the far left. Using lines and the inspect tool, I plotted out the dimensions based on this reference point.

Cutting the Part

Before running the actual part, I conducted dry runs with the "Distance to Go" screen active to check for tool collisions with the chuck. During the dry run, I noticed the tool was on track to hit the chuck, so I reconfigured the Z-axis. Once everything was properly set, I loaded the bar stock and began cutting. Throughout the process, I manually adjusted the speeds and feeds, fine-tuning the settings whenever the lathe produced unusual noises during cutting until they disappeared.

Problems Encountered

During the run, I didn’t realize that Tool 8 couldn’t cut sideways, which caused the insert to be knocked out of place and ruined the part. To fix the issue, I switched to Tool 6 instead of Tool 8. Although we couldn’t rerun the part due to time constraints, the program has been corrected and is now set up to successfully produce the part. As you can see below, the handles are unfinished and the top sphere has an unintentional little hat on it.

I am very confident if i were to rerun this fixed program, the part would come out perfect.

Final Part.

Robotics

The UniMate

The UniMate, the first-ever programmable robot, was built in 1957 and patented by George C. Devol. The first Unimate was used on an assembly line at a GM plant in 1961, where it was responsible for unloading parts.

Robots In Culinary

Robots are increasingly taking over "mindless" jobs that don’t require much thought, like making fries. Some fast food restaurants are implementing robots for this task, as it improves efficiency, saves time, and benefits workers by freeing them up for more complex tasks.

Checkpoint

First Experience with Robots:
I first encountered a robot-run café in Canada in January 2025. The entire café was operated by robots, and I found it fascinating. The hot chocolate was also surprisingly good!

Thoughts on Robotics in Industry and Society:
I see robotics as a positive development, especially in simple jobs where automation can reduce injury risks, save time, and improve working conditions. While some fear job loss, I believe robotics creates new opportunities in maintenance, engineering, and design.

One Task I Would Automate:
If I could automate one task, it would be stock trading. I would use AI to predict market trends and optimize buying and selling decisions.

Ethical Considerations of Robotics and AI:
Robots will be ethical if designed responsibly. However, there will always be individuals with money and power who may push AI to unethical extremes.

Exciting Applications and Future of Robotics:
In Arizona, I saw self-driving taxis—cars operating entirely without human drivers, using cameras and AI. While there have been some malfunctions, I believe autonomous vehicles will continue improving and eventually drive more safely than humans.

Teach Pendant vs. Lead-Through Programming

Teach Pendant Programming: Programming a robot using a tablet or pendant, allowing it to execute tasks autonomously.

Lead Through Programming: A user-friendly method where the operator physically guides the machine through desired movements, which it memorizes and replicates independently.

E-Series Core Track

I have successfully completed the E-Series Core Track course, which covers essential concepts, terminology, and programming commands for operating a UR robot. This course consists of eight modules, and upon completion, I received a certificate of completion.

Hands On Training

Loop Exercise:
We programmed the robot using a pendant by setting multiple points within a loop. After enabling loop mode, we manually positioned the robot at each desired location and saved the positions. This process was repeated to establish a full motion path. We first tested the program at a slow speed to ensure safety, then increased the speed for execution.

Dot-to-Dot Drawing Exercise:
Using a spring-loaded Sharpie, we applied the loop programming technique to create dot-to-dot drawings. We carefully mapped out the dots while ensuring the table remained stationary. During setup, we positioned the Sharpie above the paper without contact. When ready to draw, we adjusted the Z-axis so the Sharpie touched the paper and then ran the program, successfully completing the design.

Gripper Fixture

I began by inspecting the grippers and brainstorming a secure holding method. My initial design featured four arms with bolt holes for fastening, and I used the Loft tool to create a sleek yet functional base for mounting onto the robot arm.

Design 1 (Red) – Initial Concept

Designed a holder with four arms and bolt holes for securing the gripper.
Created a sleek base using the Loft tool.
Issue: The securing lip was too short, causing wobbling.

Design 2 (Blue) – First Revision

Improvement: Extended the lip for a better fit.
Issues: The lip was now too long due to a measurement error, and the arms were too weak, breaking under stress.

Design 3 (White) (Final Version)

Corrected the lip length for a secure fit.
Added triangular supports to reinforce the arms.
Replaced right angles with curved reinforcements for improved strength.
Connected the chamfered arm ends to the main structure for better integrity.

Final Outcome:

The final design is stronger, more stable, and better suited for securing the gripper.

Robot Arm Attachment

We were tasked with creating robotic arms to pick up a 1.5-inch wide nut and move it to a different location.

First Design:
The initial design featured a narrower build with contact points positioned farther apart.
Problems:

The contact points didn’t align properly when the arms were fully closed.
There were gaps at the connection points between the arms and the base that required patching.

Second Design:
For the second version, I moved the contact points closer together, resulting in a bulkier build. I also patched the base connection gaps to ensure the arms could be properly attached to the robot.

Third (Final) Design:
In the final design, I added grooves to the arms to keep the contact points secure and aligned during operation.

Robot Routine

After setting up the fixture and attaching the grippers to the robot arms using bolts, I configured the air system to control the opening and closing of the gripper arms, enabling them to pick up a 1.5-inch nut. To ensure consistent placement, I positioned the nut and traced its outline on paper as a reference for the program. I then proceeded with teach pendant programming, which involved programming the robot to pick up the part, place it down, and then return it to its original position. After adding the necessary steps, I ran the routine, and it was successful!

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