Heatcraft

At Heatcraft Refrigeration, we believe in pushing your limits. Our Co-ops have been involved with many important projects at the facility. These assignments involve product design, project management, reorganization, and cost reduction. Safety issues, long set-up times, or inefficiency issues can initiate many of these projects. All projects are aimed at improving the manufacturing process. With great mentors and friendly coworkers, you will be able to successfully complete challenging projects. Not only will you be able to get a taste of the real world; you will begin to experience success.

Click below to see some past Co-op Projects:

 

PLANT FLOOR SUPERVISING - Luke Wuthrich

Project Scope

  • Supervise tube fabrication department

Final Solution

  • Train for one week with supervisor
  • Take over full supervising responsibilities for a second week
  • Gain insight into how manufacturing really runs in the plant
  • Improve communication and management skills

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EQUIPMENT SAFETY PROJECT - Ben Gambrel

Project Scope

  • Large presses needed safety measures to prevent injuries due to reaching into the machine

Solution

  • Large budget proposal and implementation of light curtains
  • The light curtain senses if the operator is within a dangerous distance
  • If so, light curtain stops machine operation until caution area is cleared

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MAINTENANCE DEPARTMENT REORGANIZATION - Laura Misiuk

Project Scope

  • Reorganize maintenance supplies area to improve work efficiency and facility's aesthetics

Solution

  • Work with budget to purchase new cabinets and drawers
  • Manage reorganization of all supplies
  • Purchase and implement new maintenance software program
  • This was a great experience for managing, budgeting, and planning

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SAFETY AND ERGONOMICS IMPROVEMENT- David Carson

Project Scope

  • Design and implement a safe and ergonomic method for handling large packaged units on the assembly line.

Solution

  • Employ vacuum lift system.
  • The system can be operated by one person.
  • The result was a safer and more ergonomic way to lift packaged units.

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IT AT POINT OF USE - Karina Wong

Project Scope

  • Use information technology to improve efficiency of manufacturing processes and improve accuracy of material movements data.

Solution

  • Design program to integrate shop order confirmation with direct downloading of G-code from the main server
  • Utilize bar code scanners and touchscreens to simplify process
  • Eliminate unnecessary and repetitive work

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SETUP REDUCTION PROJECT - Daniel Welch

Project Scope

  • Reduce setup times and indirect labor cost in tube fabrication department

Solution

  • Design and build quick-change tooling system
  • Utilize part similarities to eliminate redundant setups
  • Replace multiple piece tooling with versatile fixtures

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WELDING SETUP IMPROVEMENT - Faye Hellman

Project Scope

  • Improve welding setups by reducing setup time and improving safety and ease of setup

Solution

  • Design new welding fixture for production parts
  • Address and eliminate ergonomic and safety issues
  • Result was a quicker and more versatile setup process

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Workstation Design - Bobby Atkinson

Project Scope

  • Optimize workstation area for ergonomics and improved workflow

Solution

  • Design new storage areas for point-of-use fastener
  • Design new work surface to improve work flow
  • Adjust placement of parts and tools for optimal ergonomic reach and distances

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Sound Calculator - David Icenogle

Project Scope

  • Create a computer program to calculate equipment sound levels for any unit

Solution

  • Determine proper formulas and integrate into program
  • Generate a user interface that can be used for standard or custom units
  • Create a database of model information linked to user interface

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Junction Box Improvement - Dean Landers

Project Scope

  • Revise unit junction box to improve customer access and usability

Solution

  • Worked with customer to understand requirements
  • Worked with manufacturing to determine limits of manufacturing equipment
  • Designed a junction box to satisfy customer needs that was easy to implement in manufacturing

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Custom Control Implementation - Justin Dunnahoo

Project Scope

  • Implement a custom control system into unit cooler product line

Solution

  • Determined all necessary controls, valves, boards, and sensors
  • Determined mounting locations for all parts
  • Created required assembly and wiring drawings for production use

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Compressor Testing - Anthony Gray

Project Scope

  • Measure compressor performance at alternate system conditions

Solution

  • Setup 4 test systems in lab with controls and data acquisition equipment
  • Compile lab test results for analysis
  • The result was a better understanding of compressor's performance

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Total Preventative Maintenance - Nathan Arnwine

Project Scope

  • Restore equipment with high amounts of downtime and implement operator maintenance.

Solution

  • Establish baseline downtime data analysis for component breakdown
  • Create operator 5S maintenance board
  • Restore equipment and replace parts with TPM team
  • Track downtime and audit the process

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Specialty Line Operations Excellence (OE) - Zack Tarter, Nathan Siler

Project Scope

  • Redesign production value stream to increase capacity, efficiency, ergonomics and safety.

Solution

  • Conduct time studies to establish baseline metrics
  • Conduct balancing & manning analysis, and redesign floor layout
  • Write CAP and purchase equipment
  • Implement kitting system for sheet metal
  • Act as supervisor of line during implementation of new process

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Ergonomic Workstation Redesign - Thomas Reese

Project Scope

  • Redesign fan assembly station to improve ergonomics of assembly operation.

Solution

  • Define initial ergonomic state with Washington Ergonomics & NIOSH lifting assessments
  • Develop prototype for potential new design
  • Design new workstation using Solid Edge
  • Order workstation and implement into the production line

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CO2 Coil Project Management - Andrew Benton

Project Scope

  • Design CO2 coils, create schedule for completion, and manage team

Solution

  • Train with mentor designing coils
  • Design, assign, and sign off coils based on production order schedule
  • Improve leadership and communication skills through managing CAD team

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