stretch wrap improvement

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Stretch Wrap Project Melvin Nays - Project Leader Richard Long - Coach Joel Brown - Sponsor 1

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Page 1: Stretch Wrap Improvement

Stretch Wrap Project Melvin Nays - Project LeaderRichard Long - CoachJoel Brown - Sponsor

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Page 2: Stretch Wrap Improvement

Problem Statement– Safety observation - employee is too close to moving part– Average Shrink wrap usage per year 139,608 ft. ($20,555)– Risk only one person (contractor) can fix current machine– Current wrapping process reduces productivity (Wrap 4/5

times)– Stretch wrap not secure which creates delivery issues

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Page 3: Stretch Wrap Improvement

Solution - New Stretch Wrap Machines

– Safe …does not require operator to lay wrap for 85% of loads

– Can be programmed to wrap different types of loads We will use 3 different settings

– Improves the stability of product during transport– Increase in pallets from 123 per roll to 147 per roll – Comes with quarterly P.M., 4 yr. warranty,

maintenance department can fix if needed and will not void the warranty

– Productivity time savings

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Page 4: Stretch Wrap Improvement

Benefits

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– Improved safety and productivity– Stretch wrap cost reduction (usage)– New machines provide a cleaner work

place environment (5S)– Reduction on freight claims

Page 5: Stretch Wrap Improvement

Benefit Analysis

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Cost Saving per year

Material cost savings $13,255

Labor saving (4 wrap machines) $102,981

Total savings $116,236

Machine price per machine $16,945

4 machines $67,780

Air lines and electric $8,401

Total expenses $ 76,181

Average operator time to wrap a pallet with old machines

4 minutes

Average operator time to wrap a pallet with new machines

40 seconds

• 58K Pallets/Year• 3 Min/Pallet• 2,900 hours

Page 6: Stretch Wrap Improvement

Summary – Equipment installed and calibrated– Personnel trained – SOP Completed– JHA Completed– Maintenance Notified and given copies of

machine specification for P.M.’s– Thank everyone for your support

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