April 18th, 2016

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Kaizen Event: Reduction of Wiring Rework Hours in MetalCLAD

Update To Ted Klee

2SPS-0159EN V01 Kaizen Report Template

AGENDA

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1. Project charter2. RACI chart3. Process Flow Diagram : Engineering / Manufacturing4. Process Failure Mode Effect Analysis (PFMEA)

• Failure Mode Cause• Severity / Occurrence / Detection (S-O-D)

5. Action Plan (short term and long term)6. Effect Benefit Diagram7. Kaizen Follow-up Calls : Sustainability

3SPS-0159EN V01 Kaizen Report Template

Confidential Property of Schneider Electric

60% of the rework cost in Metal Clad Line is due to OCNs for last 3 Months in Smyrna Plant Rework cost is calculated with the hours spent on rework that is collected on Auto time by the operators through out the manufacturing Line.

Goals/objectives

Reduce defect in wiring process from 4400 To 3500 (YTD 2015 data from quality).Reduce Rework Cost wiring by15%. Corrective actions identification and quick actions implementation from PFMEA Improve Defect Collection process to include defects through out manufacturing processSustain the new process with proper documentation, PCP record, NQC calculation correction (to include Rework Cost)

Scope Wiring: From OCN changes to Metal Clad wiring process and excludes mechanical assembly of Metal Clad and all other Production Lines.

Team

Leader : Muhammad AliSponsor : Lonnie T/David MCoach : Carrie House Process Owner : Muhammad Ali/Production Supervisor

Leadership Core Team Extended Team

QE : Chelsea Scialabba (100%)ME : Ryan Teter (50%)Application Eng : Richa Gokhale(100%) Harshada Pendse (100%)Operator : Ueursu Hall (50%)Production Supervisor : Amable Osborne (100%)Electrical Designer: Haris Shaukat (100%) Eng Supervisor : Muhammad Ali (100%)

Quality Expert : Serge LardinoisETO Expert : Herve RaoultSPS Specialist : Leticia RiveraCI Lead : Rohini B PrabhakarTesting Sup: Shana Summers (100%)

Business ImpactReduce Rework cost due to wiring by15%Reduce NQC (after correction)

Measures / KPI’s

Rework Cost Rework HoursMQD

Risk Assessment

Lead-time Impacted by Engineering Process & Tools

TimelineDefine : 02/2516 – 03/02/16Measure : 02/25/16 – 03/02/16Analyze : 03/03/16 – 03 /14/16Improve : 03/15/16-03/17/16Control : 03/18/16- 04/25/16

Causes With Brainstorming exercise , we came up with rework happening due Customer Change, Engineering Errors, Delayed customer feedback, not following correct revision of prints, Engineering documents not released in time to shop floor.

Project Name : Reduce Rework Hours in Metal Clad Production Line

Project Leader : Muhammad Ali Project Sponsor : Lonnie Tolbert/David Mabius

4SPS-0159EN V01 Kaizen Report Template >

Preparation:

Define objectiveMeasure current

state

Event:Change the

process

Sustain: Improve and control the changes

>Preparation Phase – RACI chart

RESPONSIBLE ACCOUNTABLE CONSULTED INFORMED

ENGINEERING (OCN/PFMEA/PCP)

Muhammad Ali Richa GHarshada P

Muhammad AliHaris S

Lean Master Team David MEngineering Team

PRODUCTION(Wiring PFMEA)

Amable O Chelsea SRyan T

Shana SLean Master Team

Production OperatorsChris Lee

QUALITY(NQC/ PCP)

Shana SummersChelsea

Chelsea SBrandon

Quality TeamLean Master Team

Sheri Lau &Management Staff

5SPS-0159EN V01 Kaizen Report Template

Event - Team Members (March 15-17,2016)

Preparation:

Define objectiveMeasure current

state

Event:Change the

process

Sustain: Improve and control the changes

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6SPS-0159EN V01 Kaizen Report Template

Event – ENGG PFMEA creation

Preparation:

Define objectiveMeasure current

state

Event:Change the

process

Sustain: Improve and control the changes

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1. Team was instructed to take 1.5 hrs E-Learning on Basic FMEA2. 2 Hr FMEA was provided with examples in the beginning of the Event3. Step by Step Analysis for Failure Modes, Prevention Controls,

Detection Points and Root Causes driven by Smyrna Team

Click here for detailed PFMEA spreadsheet