1. 7” Reel Current Methods of
Manufacturing Study
4/6/2014
Mark Cigich
Manufacturing Engineer
John Deere

2. Problems with Standard
• CMM time standard for 7” reels exceeds
normal working rates at least 140%
• Results in overpaying at a rate of 1:1.6
• $24,000 in overpayment annually at
production rate of $18/hr.

3. 7” Reel Blade Assembly
Assembled in three sizes:
– 22”, 28” 32”
BOM contains 76 parts,
52 unique P/N’s
Packaging included

4. CMM Process
1. Video Record manufacturing process
2. Break down Sequence of Events
3. Identify work element break-down for each
operation
4. Correctly assign work elements in Wplanner
5. Verify final analyzed time with video

5. ID Sequence of Events
• 17 sequences identified in assembly from sub-
assembly to packaging
• Each uploaded into Wplanner
• Work elements assigned to each sequence

6. Wplanner Module - Breakdown
Adjusting Rod Assembly Qty SEQ Time (m)
1Carry part 0.5 lbs < 3 ft. 1 0.18
2Secure clamp (3") 2 0.04
3Pick, Place and Drill pin (1) 2 0.12
4Remove clamp (3") 2 0.04
4Insert washer 5 0.15
5Aside assembly 1 0.04
Total SEQ 0.57
Work elements
Element Times
obtained from
Wplanner database

7. Correct CMM Standard Created
SEQ Event SEQ Time
1Adjusting Rod Sub Assembly 0.57
2Blade Adjuster Sub Assembly 0.96
3Deflector Sub Assembly 1.03
4Adjustor Housing Assembly 2.58
5Pivot Housing Sub Assembly 0.58
6Pivot Housing Nut Install 2.65
7Install Reel 2.92
8Adjustor Housings to Frame 2.94
9End Cap Install 0.65
10Cover Installation 3.32
11Adjustor Rod to Frame 2.02
12Adjustor Housings to Frame 3.15
13Blade Adjustment 3.03
14Attach Labels & Wipe 0.40
15Install Pallet 0.74
16Reel to Pallet 1.10
17Crate Unit 3.71
Total Time 32.35
SEQ Event
SEQ
Time
1
ADJUSTING ROD AND BLADE
ADJUSTOR 2.55
2DEFLECTOR 2.08
3
ADJUSTOR HOUSING AND
PIVOT 3.53
4PIVOT NUT 2.65
5REEL INSTALL 2.86
6
ADJUSTOR HOUSINGS TO
FRAME 3.52
7COVER 3.97
8ADJUSTOR ROD 2.52
9ADJUSTOR HOUSINGS 4.15
10BLADE ADJUST 3.03
11REEL TO PALLET 3.10
12CRATING 6.71
Total Time 38.12

8. Results and Wages Saved
• Inaccurate 5.77m added to time study
• Correct CMM results in 5.77m saved
• $24,000 in labor to be saved annually

9. Acknowledgements
• Dan Gibbs, Manufacturing Engineering
Manager for sponsoring
• Ryan Voy, Manufacturing Supervisor for
coordinating
• Wilfredo Rodriguez, Manufacturing Engineer
in coaching