manufacturing kaizen

8/9/2019 Manufacturing Kaizen

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Lean & Six Sigma Integration Specialistswww.wyrickenterprises.com 949-461-0279

Companion LineKaizen Event


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LOT SIZE RULE

Make One

Move One

Companion Line Flow

INDIVIDUAL EFFICIENCY VS. SYSTEM EFFICIENCYINDIVIDUAL EFFICIENCY VS. SYSTEM EFFICIENCY

We are committed to overall system efficiency rather than just the

efficiency of individual processes. We are a TEAM!


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Kaizen Mandate

Eliminate waste

Create a more efficient layout

Implement and sustain 5SCreate a tracking and reporting system


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Project Scope

5S the work area

Redesign the work areaFlow and flexibility

Visual workspace, point of use tools

Cost effective

Define/ implement min/ max inventory levels

Eliminate waste

Create Communications Board with measuresDocument Non-conformance issues

Standardize work (SOP)


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Kaizen DeliverablesCreating Shorter, Simpler and Smoother Processes

Establish ground rules Create a team charter

(scope, boundaries, expectations, deliverables, ROI)

Develop a current state map Identify necessary data, people, resources

Determine Metrics and Indicators

Incorporate data and metrics into currentstate map


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Kaizen DeliverablesCreating Shorter, Simpler and Smoother Processes

Create detailed future state map Perform Gap analysis

Assign teams for immediate process changes

Assign teams for long term system changes Implement immediate changes

Document and quantify improvements

Create time-lines and follow-through plans

Prepare and present report-out


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Lean in Action


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Lean in Action


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Old Layout of Work Area


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Old Process Flow Map


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Original Spaghetti Diagram 1Pull Order Flow


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Original Spaghetti Diagram 3Companion Unit Flow


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Original Time and DistanceTotal Time = 2253 min

Total Distance = 8908 ft

Total VA Time = 690 min

Total Steps = 54Total VA Steps = 19


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BEFORE Pictures


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BEFORE Pictures


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BEFORE Pictures


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Non-ConformanceService Calls

2 Methods to Resolve

Phone

3rd party service provider @$95/hour

Average Service Call = $800Total Companion Service Calls = 756

Total Cost of Service Calls = $604,800

16 Out of Box Failures


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Non-ConformanceCompanion PARsand Deviations

59 PARs since March 2003

45 Deviations in last 3 months

Estimated cost of $100 per deviation

Cost of deviations last 3 months = $4,500

Companion communicator spends 8 hours per

week sorting and tracking documentation forthe area


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Non-ConformanceCompanion Rework

Time/Labor Cost

67% of rework time is due to engineering changes25% is due to bad parts

Cost for week of June 13, 2005 = $2,800

Annual Cost = $145,600

Vendor errors(vendor errors of fabricated items are generally fixed by assembly personnel and nocost is captured. Items not able to be repaired by assembly are sent to the machineshop. Samples are:

Side panels: broken welds (30), 6 hrs, $259Stud and paint: 196 parts, 5.25 hrs, $218


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Non-ConformanceCompanion Rework

Samples of items returned to vendor

Mother board, 27 bad out of 349 (7.7%) sinceFebruary 2005

Pump board, 97 bad out of 504 (19.2%) since

January 2005

Cable set D, 39 bad out of 340 (11.5%) sinceDecember 2005

Display cable for touch screen, 82 bad out of 254(32.3%) since December 2004


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Non-ConformanceSummary

We do not track nonconformance very well.

A lot of rework is done by assembly personneland the cost is not captured. However, fromthe data we do have, it is easy to see that

vendors are hurting the Companion assemblydepartment.

92% of the rework is generated outside of the

department, but it cost the department anannual average of $145,000 to fix it.


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New Layout and Flow of Work Area


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AFTER Pictures


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AFTER Pictures


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New Time and DistanceTotal Time = 822 min

Total Distance = 190 ft

Total VA Time = 578 min

Total Steps = 31Total VA Steps = 7


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Return On InvestmentReduction of overall time by 36% (1431

minutes)Reduced movement by 7908 feet

Total steps reduced from 54 to 31Value added increased from 31% to 70%

Expenditures for the event = $7,500 (see30/ 60 day action plan for details)


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Return On Investment

Overall benefit is an increase in capacity torun at 4 units per day from 2.1 units per day.

This translates to a cost savings of $5400 perunit.

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