aug ma 5s and visual management - mfrall.com · carl zeiss industrial metrology , llc, dale...
TRANSCRIPT
8/11/2016
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Good Morning!
Manufacturers AllianceSharing Education & Resources Peer-to-Peer
Welcome
Kirby Sneen, Vice President
Manufacturers Alliance
Please silence your phones during the
presentations and discussion.
A PDF copy of today’s
slides will be sent to you after the event.
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Thank you to our host
Thank you members
Member Companies may send up to five employees to Educational Seminars and Webinars at no cost.
Bauer Welding and Metal Fab Boston ScientificCentral Package and Display DDL Inc.Dynamic Group Electric MachineryFlexmation Inc. Force AmericaGeneral Dynamics Graco Inc.Heraeus NeoMetrics Imperial Plastics Inc.JEM Technical Liberty Carton CompanyLifeHealth LLC Medtronic Inc.Metal Craft Machine Midwest Rubber Service and SupplyMikros Engineering Inc. Millerbernd ManufacturingMOCON Inc. Modern MoldingNystrom Inc. Olympus Surgical TechnologiesPrecision Associates PGCProMed Molded Products REO PlasticsReviva Synergy HealthTurck Inc. Tillges Certified Orthotic ProstheticUpsher-Smith Labs Vista Outdoor
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Member Resources
2016 Wage Survey 207 company participants, 175+ positions included
Available to purchase now
Job Postings & Resume Listings Skilled, Technical, and Management positions, 350+ views per day
Members may post openings at no cost
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Doug Sparks
• Owner/Operator of 4 separate businesseso 2 of which are dealing directly with World Class
Manufacturers.
• 30+ years of operational experience o Common sense approacho Highly effective results.
• Over 500 separate facilities and 10,000+ peers, trained
• Shingo Prize Recipient
• 2004 Manufacturer of the Year
• Several Patents
What is Value Added?
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What is Value Added?
Direct Bolt Every joint used by Flex Craft features the use of 5/16”
bolts.
Universal Joint
How does it work?
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Phone: 1‐877‐565‐3539
Email: info@flex‐craft.com
www.Flex‐Craft.com
Moderator
Jeff Meyer-Quarberg,
Principal Process Improvement Analyst
Boston Scientific
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Millerbernd Manufacturing
Eric Quast
Emily Lewerenz
Continuous Improvement Technicians
Agenda:• History • Ring and cylinder division
• 5S• Visual Management
• Pole Division• Visual Management
• Wrap up
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600K Sq. Ft. / 350 Employees / 55 Acres
Millerbernd Manufacturing Company
622 6th Street SouthWinsted, MN 55395
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Ring and Cylinder Division
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Visual Management
• Issue
• Mission
• How?
• Start of Process
Sales order log
Visual Management
• Flag Visual
• Information tracking
• Std. Work
Sales order
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2 years ago
• 6-8 week lead time• Order status• Some orders 6-7 weeks
past due• No consistency (cherry-
picking)• “top 30” List• Focus changed daily• Abundance of Job
Orders on the shop floor
• Batch Processing
What did we do about it• Admitted that we had
a problem
• Held a week long event• Needed a system that
was simple yet effective
• Needed to sync up all areas of production
• Included all players in the process
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Event Results
• Daily Pitch Scheduling!
• 3 week rotating schedule
• Job Orders printed when needed
• Main Production Board
Challenges to Implementation
• Resistance to 1-piece flow from batching
• Stock to Make (inventory system)
• Increase in paperwork
• Communication
• Team Scheduling
• Updating the board
• Accounting for attributes
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Visual Area Boards
• Area status at a glance
• Updated by operators in the area
• Tracked by leads
• Checked by management
• accountability
Successes• 3 week lead time in
the shop
• Easy tracking of order status
• Team communication at daily production meetings
• Controlled WIP
• Changes handled with ease
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5S and Visual Management
Boston Scientific, 2016-08-11
Dale Williams
362016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
Company History
Carl Zeiss AG, is a company founded in 1846 by amechanic of the same name. Known as one of thebest in the field, ZEISS set the bar high formanufacturing in optics. Today Carl Zeiss AG hasa portfolio that covers consumer optics, industrialmetrology, medical technology, microscopy,semiconductor manufacturing technology,spectroscopy, and vision care. While the companyis headquartered in Oberkochen, Germany,facilities from each of the businesses surround theworld. One of those companies is located here inMaple Grove, Minnesota. The facility in Minnesotais a branch of the industrial metrology business(metrology is the science of measurements)having approximately five hundred employees, butsupports all of the Americas with its production ofCMM products, as well as the services required tomaintain them.
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372016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
Company History
382016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
Product Description
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392016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
Product Description
A coordinate measuring machine, orCMM, is a machine commonly used inmanufacturing for quality assurancepurposes. This machine, with the helpof a computer and operator, canmeasure the geometric properties of anobject down to the micron level. Amicron is 1/1000 of a millimeter, andcannot be seen with the naked eye.After an object is secured on themeasuring surface of the machine, themachine can use a variety of differingprobe options to take measurements in20K plus positions and compare theresults to required specifications.
402016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Production Board
• A monitor can be found at the end of each product line and is maintained by technicians
• Software developed in house
• Web based
• Communicates with SAP
• Tracks product orders through entire production process
• Information is in real time
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412016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Training Board
• Tracks every technicians proficiencies in various jobs/roles on the production floor.
• Provides visual for both mangers and technicians on progress
• Tracks and visually displays production training plans in a full year view.
422016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
CPO/CAPA Board
• Monitors floor wide CPO (customer perfect order) results
• Acts as a tool for monitoring and eliminating active CAPA (corrective action/preventative action) issues
• Managers meet weekly at board to discuss progress
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432016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Production Cell Status Stands
• Displays customer name, work order number, and progress dates for machine being built
• Shows potential risks to CPO (customer perfect order) and its sub metrics OTD (on time delivery), EF (equipment functionality), and OC (order complete)
• Wheel provides production status of the cell and reason if there is a delay.
442016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Stack Lights
• Attached to each work station
• Provides high level visual status of a particular cell
• Easy to see from a distance
• Connected to network
• Provides real time stop/start information to production managers via web page overview, and text message
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452016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Line Board
• Each line has a board where line specific metrics are displayed
• Metrics are displayed in day, week, and month format, showing positive or negative trends
• Other information displayed includes yearly goals, and monthly CPO results
• Production managers manage to these metrics in their morning meetings
462016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Kanban
• Set up in stoplight fashion
• Adjusted by production planners
• Cards print automatically through SAP system when part is scanned empty in warehouse
• Visually cues technician to the parts needs of the warehouse, as well as the urgency at which parts are needed.
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472016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Floor Tape and Color Coded Carts
• Floor taping designates locations and boundaries
• These include:
• Material cart locations• Work cart locations• 6S cart locations• Work cell boundaries• Walking paths/aisle ways• Etc.
482016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
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492016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Cart Signs
• All work carts have large signs to assist warehouse personnel in locating carts for two bin system parts refills.
502016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Divider Walls
• Used to designate/divide production line areas
• Dual purpose as they also act as temperature control for machine testing
• Adds a “wow” factor for guest tours
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512016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Flags
• Green flags are used as a visual signal to the shipping department when machines are complete and ready for pickup, bracing, and packaging.
522016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
Foam Tool/Fixture Organization
• Foam is used throughout the production floor to organize tools and fixturing
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532016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
542016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
5S and Visual Management
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552016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production
Conclusions
Break
Take 10 minutes and
meet someone new
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Dynamic Group
Steve Kalina
President
Dynamic Group
5S & Visual Management
Steve Kalina
President
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Origins
•World Class Precision Molds & Molding
•Dynamic Engineering and Dyna‐PlastBrought Together
• Expanded Capabilities
•Dyna‐PlastMolding
•Dynamic Engineering Founded by Dave Kalina & Peter McGillivray
Precision Molds & Molding
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Who we Serve• Niches
• Small• Extremely Complex
• Tight Tolerances• High Throughput
• Industries• Medical• Dental• Defense• High Precision
Medical Device Contract Manufacturing
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Why 5s and visual management?
1. Perception is reality
2. Communication/Team‐work3. Consistency
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Why 5s and visual management?
1. Perception is reality
2. Communication/Team‐work3. Consistency
4. Life is easier!
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Lessons Learned
• Begin with Culture
• Find the champions, get their buy‐in and then let them flourish
• Keep it Simple
• Start with small changes. Hundreds of little impacts driven by many will usually drive more long‐term success than a few large changes driven by a few
• Get Started!
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Thank you!
Steve KalinaPresidentDynamic Group, [email protected]‐792‐1278
Q & ACarl Zeiss IMT Dale Williams
Millerbernd
ManufacturingEric QuastEmily Lewerenz
Dynamic Group
Steve KalinaModeratorJeff Meyer-Quarberg
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How did we do?
Please fill out your feedback sheet for today’s seminar.
Seminars & WebinarsModern Day Kaizen EventsWebinar August 19 online or Live at Manufacturers Alliance in Golden Valley
Performance Metrics With PurposeSeptember 8 at Normandale
Standard Work for SalesOctober 13 at Dunwoody
TPM and Predictive MaintenanceWebinar October 28 online or Live atManufacturers Alliance in Golden Valley
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WorkshopsEngaging Your Workforce in Daily Improvements August 16
Finance and Accounting for Non-Financial Managers Sept 13-14
Lean in Contract ManufacturingSeptember 15
Lean Product DevelopmentSeptember 20
NEW Corrective Action/Preventive Action (CAPA) September 28
NEW Coaching for Continuous Improvement October 4
CertificationsLean Practitioner Certification
Series starts September 7
Supervision Fundamentals CertificationSeries starts September 8
Six Sigma Green Belt Certification Series starts October 5
Lean Leader Certification Series starts October 13
Flyers on the back table!