brake press plasma set-up reduction 3-28-08
TRANSCRIPT
1
Lebanon Kaizen Event #13 Hard Dies Work
March 24-28, 2008
2
Team MembersName Area Service Yrs
•Team Leader: Howard Peterson Lean Tech 5 •Sub T/L: Richard Holliday Fabricator A 2•Member: Travis Officer Bass Line Hull Welder A 7•Member: Johnny Evans R&D 8•Member: Wes Wellman Fence dept. Supervisor 16•Member: Jon Meadows Fence Lead (2nd) 8•Member: Lance Schmidt Fab Lead (2nd) 9•Member: Terry McMahon R&D 18•Member: Bobby Baker Safety Manager 17•Support: Ted Edson KPO Manager 4•Consultant: Jonathan Wheatley (TBM)
3
GoalsActivity Current Goal
1 One safety improvement per each team member - 9
2 Improve 5S by one point 1.5 2.5
3
4
Reduce Brake Press Set-up time 35Min 75%
Reduce WIP in Hull Fab & establish Standard WIP 86 25%
5 Write, verify & implement Standard Work 0 Complete
4
Area Layout
NIAGARA 350 T
PLASMA
UNCOILER
WELD LINE1
WELD LINE3
WELD LINE2
Supervisor Office
5
Safety Improvements
Item Description of Improvement Hazard Type Eliminated
1 Clear blocked Fire Extinguisher Fire
2 Repair Leaking fluids from the press Slip
3 Better accessibility to the Press E-Stop Crush
4 Shorten or add Coil hose Trip
5 Remove old welding curtain Trip
6 Reduce Lifting & flipping boats by hand Strain/Ergo
7 Safety block chained to Press bed (was under the table) Crush
8 Reduce number of trash cans in area Trip
9 Reduce amount of pushing carts around (Establish Standard WIP) Strain/Ergo
10 Tighten/replace guarding on Plasma machine Pinch
11 Reduce exposure to sharp edges (use hand suction cups) Cut/strain
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Improve Safety
Before:
Safety block under the table
After:
Attached safety block to bed
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Brake Press Set-Up Reduction
0
5
10
15
20
25
30
35
Op A Op B Op C Op D
CurrentExt from IntStreamlined
8
Plasma Set-Up Reduction
0
2
4
6
8
10
12
14
16
Op A Op B
CurrentExt from IntStreamlined
9
Before 5S
10
After 5S
11
Press Capability
28252219161310741
10.5
9.5
8.5
Indi
vidu
al V
alue
_X=8.917
UCL=10.017
LCL=7.816
28252219161310741
1.6
0.8
0.0
Mov
ing
Rang
e
__MR=0.414
UCL=1.352
LCL=0
3025201510
9.6
8.8
8.0
Observation
Valu
es
12.011.210.49.68.88.0
LSL USL
LSL 10USL 12
Specifications
111098
Within
Overall
Specs
StDev 0.366838Cp 0.91Cpk -0.98
WithinStDev 0.526592Pp 0.63Ppk -0.69Cpm *
Overall
1
1
Process Capability Sixpack of Bend "11"I Chart
Moving Range Chart
Last 25 Observations
Capability Histogram
Normal Prob PlotAD: 2.493, P: < 0.005
Capability Plot
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Before Material Handling
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Kaizen Improvement (Trystorming)
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Kaizen Improvement Proposal
Drawing underway
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Kaizen Improvements - Plasma
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Line Balancing
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Work In Process Current & ProposedLocation Current Proposed Delta
Hull Press Staging Area 28 16-25
Weld Line 2 Staging Area 34 5
Weld Line 3 staging Area 24 8
Totals 86 41 53%
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Operation Number: 1 of 1
SWIP
Step # Cycle Time CTQ's CTS
12345
6
78
9
10111213141516171819
Total 0
With the assistance of helper, remove cut parts from machine table onto the file table
Run another hull & after the first part is completely filed and inspected, put it on the corrugation table & cover with carpet
Repeat steps 7&8 until the daily requirement for this coil is met
Description of Work Content
Last 15 min. of shift
Clean your areaVarious
Push back the stop table in place & make sure it latches in place
Make sure the coil is in a safe position to cut the band or loosen the ratchet and do so
Standard WorkIssued by: Approval Date:Takt Time
13 Min
Feed Coil through & adjust for flatness. Keep fingers away from rollers. Wear gloves as material has sharp edges
Tony Williams 3/28/2008Safety/Hazard Controls:Tools Required:
Production Steps: Square material and select correct program. Cycle start
Set - Up Steps: Check the Decoiler & make sure it is out of gear
Model
Various
QUALITY POLICYWe are committed to delivering quality and value to our customers by; complying with customer and Quality Management System (QMS) Requirements, continuous improvement to our product and internal systems, and achieving our quality objective
PPENIAGARA 350 T
PLASMA
UNCOILER
16-25
5
8
WELD LINE1
WELD LINE1
WELD LINE1
0
Supervisor Office
19
External Pre-Setup Checklist PLASMA
All Items Pre-Setup 10 Minutes Before Setup
Initial When
Complete Pre-Setup Items Responsible
Person Initial When
Complete Pre-Setup Items Responsible
Person
Coil stock & Forklift available
Plasma helper & Fork Lift driver
Ratchet with 1 -7/8 Socket
Plasma Helper
Plasma Tips Plasma Operator
PPE & Tape measure
Helper & Operator
Suction cups Helper
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ResultsActivity Current Goal Result
1 One safety improvement per each team member - 9 9 of 11 implemented
2 Improve 5S by one point 1.5 2.5 2.5
3 Reduce Brake Press Set-up time 35Min 75% 66%
4
5
Reduce Plasma Set-up time 15 75% 78%
Reduce WIP in Hull Fab & establish Standard WIP
86 25% 53%
6 Write, verify & implement Standard Work 0 1 per operator
Complete
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30 Day Items
Item Action Who When
1 Design & Fabricate hull handling equipment Terry 4/27/08
2 Post Standard work on each station Larry 4/6/08
3 Establish Press program back-up method Ted 4/6/08
4 Press positioning is not repeatable - TBD TBD
5 Implement TPM checklists for Press and Plasma Operators
Howard 4/27/08
6 Move Plasma Exhaust box out of the traffic area John/Lance 4/6/08
7 Identify and stock Long lead-time spare parts for the Press & the Plasma
Wayne King 4/6/08
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Questions?