Trust Technologies – Mentor, Ohio

Sept 8 – 10, 2009

Trust Technologies, Inc – Mentor, Ohio

Waste Reduction Workshop

F119 Cell Pt # 524P235-01

The TEAM

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Trust Technologies – Mentor, Ohio

Agenda – Hoshin Workshop• Day One 8am to 4pm

• 20 Principles & 7 concepts of Lean –John Petak

• 8 Forms of “TIM WOOD “ Waste – John Petak

• 6 Rules of Quality – drive Quality First concept – John Petak

• Defined 17 process steps VA 41% NVA 59% - Team

• Defining the Current State VSM – Team (High Level Map) -Team

• Calculate Takt Time for 4 part references TT = 114 minutes or 6857 sec - Team

Trust Technologies – Mentor, Ohio

Agenda Hoshin Workshop• Day Two

• Review day one findings / lessons learned

• Gather inventory data on all 17 process steps ( 85.7 days)

• Kaizen Process overview with A3 Report out , Business case establish

• Build current state metrics ( Distance part travels, inventory, manpower, cycle time, changeover time and first time yield or FTQ).

• Construct future state map and U shaped cell

Trust Technologies – Mentor, Ohio

Agenda Hoshin Workshop• Day Three

• Review the past two days

• Prepare new layout without “Tim Wood” waste

• Build Plan, Do, Check and Act worksheet

• Finalize A3 Report out

• Measure equipment footprint to construct new layout

• Management Report Out

Trust Technologies – Mentor, Ohio

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Action Plan

Trust Technologies – Mentor, Ohio

General Observations 1. Excessive walk time from incoming receiving to shipping department (968’

or 324 yds)

2. Downtime not tracked and recorded daily to drive uptime in cell

3. Visual management with daily information need to run production ( KAN BAN Pull system, super markets)

4. Quality Defects or FIRST time Yield needs to be implemented

5.Train all associates to QMM standards

6. Point of use , real time of VA work.

Trust Technologies – Mentor, Ohio

Flow Oriented Layout• Definition

• Designing physical work space that supports a logical flow of all materials in the production area.

Opr #20 Inspection & Shipping , 500 & 600

VALUE ADD

F119 Cell Analysis

Future State Map – F119 524P235 - 01

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Trust Technologies – Mentor, Ohio

New Layout

F119 Cell Recommendations

Move Processes in Line Manual/Tumble Deburr Wash Inspection Packing

Re – Layout Cell to significantly reduce Travel Times

Analyze and Balance Work Content