revised tour presentation 2009 - virginia tech · 2014-09-08 · poka-yoke (mistake proofing) 2002...
TRANSCRIPT
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Welcome to
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Duncanville
Cedar Hill
Atkins
Ocala
Rapid City
Masco BCG Manufacturing Locations
Jackson
Albuquerque
Mt. Jackson
Mt. Sterling Culpeper
Adrian
(Corporate)
Assembly Plants
Component Plants (6)
(6)
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Atkins, Virginia (Door Plant)
•! Plant Type: Component
•! Primary Brand: Merillat
•! Size: 278,320 Sq. Ft.
•! Hourly: 260
•! Salaried: 20
•! Primary Operation:
•! Coped Veneer Panel Doors
•! Secondary Ops:
•! Lumber Drying
•! Rough Mill
•! Drawer Fronts
•! Frame Stock
•! Finishing (Doors, Drawer Fronts)
•! Mitered Doors
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Atkins, Virginia (Panel Plant)
•! Plant Type: Component
•! Primary Brand: Merillat
•! Size: 140,610 Sq. Ft.
•! Hourly: 127
•! Salaried: 6
•! Primary Operation:
•! Veneered Door Panels
•! Secondary Ops:
•! Veneered Accessories
•! Finishing (Frames, Doors, Drawer Fronts, Accessories)
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To build a lasting system and culture that drives continuous improvement in the value stream of the organization, while developing leaders for the future.
Objective
Culture is more important than the short term results –
Continuous Improvement is part of the BCG DNA
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The setting of standards aimed at waste
reduction with participation by all.
resetting and sustaining
BCG Continuous Improvement
Philosophy
Apply Tension
& Tighten
To Expose Waste
Set New
Standard
Adherence
To Standard
Evaluate
Waste & Improvement
Opportunities
Charter
Projects
Manage &
Coach Projects To
Completion
Prioritize
Projects
Management
System
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BCG Production System – “Lean
House”
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BCG CI Strategy 2009
Design of
Experiment
events,
Maintenance
Excellence,
Zero Defects
2011
Making
materials flow,
Maintenance
Excellence
Platinum Level
2013
Value
Stream
Mapping
extended
2010
Job Relations,
Job Methods,
Job Safety, SPC
training
2012
DMAIC
teachers (Black
Belts) in all
locations
1999
Standard
Work, Job
Instruction
Training
2001
Value Stream
Mapping, 7
Principles of
Warehousing,
Heijunka
scheduling
2003
Design for
Six Sigma
(Green Belt);
Shingo Prize
2005
Six Sigma
Orange Belt
(DMAIC)
1998
Define MPS
House, Kaizen
Process 5S,
Accountability
Meetings
2000
Poka-
Yoke
(Mistake
Proofing)
2002
Six Sigma
Green Belt
(DMAIC),
Team Leader
Development
2004
Six Sigma
Black Belt
(DMAIC), Total
Preventive
Maintenance
2006
MPS Training
Standards,
BCG Six
Sigma
Training
2008
TPM
Certification, 5S
Certification /
Standard, Shop
Floor Problem
Solving
2007
MPS Tools
Certification,
Setup Reduction
Certification
Continue Establish CI Pace
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The Results of Lean Manufacturing
Company
Merillat
Atkins
Quality
72%
WIP
Reduction
87%
Ship
On
Time
99.7%
Equipment
Uptime
99%
Quoted
Lead Time
Reduction
5 days ! 8 hrs.
•!Freed up 200,000 sq. feet of floor space
•!Added 3 additional species of product: hard maple, soft maple and cherry
•!Average lot size went from 200 down to 20 pieces
•!Quadrupled the number of SKU’s to 18,000
•!Plant capacity doubled with no capital
•!Reduced CTS Veneer inventory by 950,000 ft.
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Accomplishments
•! Capacity
•! Core business
•! Nationally distributed product
•! Inventory turns
•! Cut direct
•! No finished goods inventory
•! Quality
•! Standard Work
•! Poka-Yoke
•! Six Sigma
•! Glass House
•! Conduct standard work audits daily.
•! Graphical display of measurable.
•! Team problem solving.
•! Standard Environment
•! A place for everything.
•! Beginning of shift audit system.
•! Parts delivery system (carts).
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Masco Builder Cabinet Group
(Typical acceptance of the MPS)
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The Pile-On Vision
“Program of the Month”
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No Traction!!
Your initiatives
Your organization
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Six Sigma @ Atkins
•! Began in 2002
•! 55 Juran Certified Orange Belts
•! 10 Juran Certified Green Belts
•! 1 Juran Certified Black Belt
•! 20 Projects per year
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Kaizen Event
•! People System •! A Cause, Not a Job •! Three to Five Days
•!Training / Data Collection / Solution •!Implementation •!Monitor to Sustain
•!Frequency - Quantity leads to Quality
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Kaizen
•! 293 Kaizen events from 1999 to YTD
•! 492 Different Participants
•! People System
•! No one looses their job!!!!!!!
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Where did we begin?
5S Is The Foundation
Before After
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Kaizen
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Kaizen Example – Manufacturing
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Kaizen Example – Branch Warehouse
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7 Principles of Warehousing – Vertical Storage
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One Pass Aisles / Vertical Pick
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Heijunka
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The Results of Lean Manufacturing
•! WIP reduced by 80%
•! Implemented the Atkins Cart System
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Atkins Cart System (ACS)
Before
After
Before
•!Removed 2,360 ft. of conveyor
•!Reduced WIP from 180,000 pcs.
to 13,000 pcs. 93% improvement
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Implement Vision
•!Steering Team
•!Value-Stream Mapping
•!Future State - 3 month timing
•!Kaizen Bursts
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Top-Down Mandate
Examples
•!“100 Poka-Yoke devices by the end of the year” per
plant
•!“30 Kaizen events this year” per plant
•!“20 DMAIC projects this year” per plant
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Next Steps
•! Benchmark
•! Revise Next Future State
•! Mix in Top-Down Mandates
•! Increase Kaizen Event Pace (Drive to the shop
floor)
•! Continuously Improve -- Do it again!
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The key to our Success…is our People!!!
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THANK YOU