Lean Deployment Status

2010

2

Status Tracking

PLANT:

X5 IP Foaming-- 105 12-May-05X5 Small Parts Foaming--106E85 Foaming -- 122 14-May-05X5 IP Seq. Center -- 216X5 IP Assy-182 13-May-05X5 Glove Box Assy--184X5 Console -- 109 13-May-05E85 IP Assy--152E85 Console--155E85 Glove Box--156E85 Sequencing--251

X5 Door Panels -- 107X5 Edgefold -- 110Glue -- 1132 (BMW)

Assembly -- 1142 (BMW)

Hot Press -- 116GMX Shipping--117GMX Assembly--172GMX Welder--173GMX Laser--174GMX Inspection--175X5 DP Seq. Center -- 215

Injection --112Back Press -- 113Vac Form -- 101Paint -- 102X5 Bulk--183X5 Bulk and Pass-Thru -- 111X5 Waterjet -- 151E85 Waterjet--153

Shipping-Spare Parts--120

date exist

Fountain Inn

PSE deployment status

UAP Production line

Time measurement

date

Logistics Lori Morgan

UAP 2 Gerald Mentil

UAP 4 Lisa Stanton

UAP 3 David Hunter

exist existdate exist date exist date

Cycle Time Diagramm Standardised Work Chart Standardised Work

Combination TableJob instruction

(Standard Operation)

3

Measurement of Cycle TimeMEASUREMENT OF CYCLE TIME

FOR SYSA 009 e /1

Product Workstation Layout:

Process Analyzed by

Date Time

N° Basic action 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

OBSERVATIONS f

a g

b h

c i

d j

6

7

8

Cycle time

operating time without waiting

5

9

10

1

2

3

4

4

Cycle time diagram

• Eliminate cycle time fluctuation

• Challenge cycle time with Takt Time

WC = 203’’ WC = 203’’

5

Standardized Work

Operation from: Date:

to:

Takt Time Expected nb parts waiting

61 s

Cycle time

51 s

Expected number of parts waiting

3

FAU-F-PSE-006 /1

Product: panel Process: welding, assembly

Standardized work chart

Machine 4 (Welding)

Station 5 (Inspection)

FP cart12

3

4

5

6

710

8

9

Qualityinspection

Safety

Movement

w ith part

w ithout part

Productionname:

date:

Methodsname:

date:

Qualityname:

date:

6

Standardized Work

/ / / / / /

PRODUCT REFERENCE NUMBER:

WORKSTATION ANALYZED BY:

TAKT TIME: Quality

Volume:

DATE:

Production Methods

STANDARDIZED WORK COMBINATION TABLE

TIME OPERATION TIME

WALKAUTOMANUOPERATION NAME

N° 45 6015

2

3

35

3

2

4Functional inspection 3

310Position part for inspection

3 Weld

Welding inspection

2

3

Pick waiting part

2Position part

1

5 15

Place part in cart

9 Pick welded part

2

7 Pick inspected part 2

Surface inspection

5

6

8

3

50

3

34

25

2

555 10 403020

CT = 51s

TT = 61s

FAU-F-PSE-007 /1

7

Standard Operation Procedure

No.

1

2

3

4

5

6

7

8

9

10

Page No:

Work-station:

Line :Part NamePart

Number

= TIP

Document No.:STANDARD OPERATION Plant:

Operation = SAFETY = QUALITY Sketches / Photo's / etc.Time:

1/1Revision Level:

FIS-F-PS-241 / ENversion 02

P lace rejects in reject container. Record on P rocess Monitor Sheet. If 3 or more rejects found with same fault call Gap Leader.

Name: Name:

Non Conforming Product:

Function:

Signature/DateIssued Checked SKILLEDOPERATOR

Signature/Date

Function:

Signature/Date

Name:Function:

Name:

Signature/DateApproved

8

Tracking of Production (TRS)TRACKING OF PRODUCTION PLANT:- GAP:- Date:-

Product.Prog.

stops

Change-

over

Org.

prob.

Break-

dow nsRemarks Product.

Prog.

stops

Change-

ov er

Org.

prob.

Break-

dow nsRemarks Product.

Prog.

stops

Change-

ov er

Org.

prob.

Break-

dow ns

15:00 23:00 7:00Total Total Total

Part No. Product O.K. Productive time Part No. Product O.K. Productive time Part No. Product O.K.

+ ++ ++ +

Total = Total = TotalTRS TRS TRS

Standard cycle tim e (s)

7:00 15:00 23:00

Standard cycle tim e (s)

Standard cycle time (s)

9:30

9:00

8:00

7:30

11:00

11:00

10:30

10:00

13:00

12:30

12:00

11:30

6:3014:30

14:00

13:00 21:30

22:00

22:30

4:30

5:00

5:30

6:00

2:30

3:00

3:30

23:30

0:00

0:30

1:00

1:30

2:00

4:00

19:30

20:00

20;30

21:00

17:30

18:00

18:30

19:00

15:30

16:00

16:30

17:00

xxx

===

xxx

===

xxx

==

=

9

Tracking of Production (PPH) TRACKING OF PRODUCTION - Assembly line PLANT: Line: Date:

06H00Product.

Prog.

stops

Change-

ov er

Org.

prob.

Break-

dow nsRemarks

14H00Product.

Prog.

stops

Change-

ov er

Org.

prob.

Break-

dow nsRemarks

22H00Product.

Prog.

stops

Change-

ov er

06H30 14H30 22H30

07H00 15H00 23H00

07H30 15H30 23H30

08H00 16H00 00H00

08H30 16H30 00H30

09H00 17H00 01H00

09H30 17H30 01H30

10H00 18H00 02H00

10H30 18H30 02H30

11H00 19H00 03H00

11H30 19H30 03H30

12H00 20H00 04H00

12H30 20H30 04H30

13H00 21H00 05H00

13H30 21H30 05H30

14H00 22H00 06H00Total Total Total

Part No. Good parts Factor Equivalent good parts Part No. Good parts Factor Equivalent good parts Part No. Good parts Factor

+ +

+ +

+ +

+ +

Total Total

Manpower Hours Manpower Hours Manpower Hours

Parts / Person / Hour Parts / Person / Hour Parts / Person / Hour

x

x

x

=

=

=

x

x

x

=

=

=

x

x

x

x == =x x

/

=

=

/

=

=

10

Tool Change Over TrackingPress:

Tool No. / part ref.

Number of parts

Start time ObservationsDate

TOOL CHANGEOVER TRACKING

Changeover time graphChangeover

Duration

FOR SYSA 005 e /1

11

Parts Board

DATE SHIFT

Hour ObjectiveGood Parts

LHDGood Parts

RHD

1

2

3

4

5

6

7

8

9

TOTAL

PARTS BOARD

Comments

GAP LEADERLINE or CELL

12

MIFA / MIFD

C/O=TT = CTO = WC =

PRIMINGC/O=TT = CTO = WC =

DRYING OVENHINGE ASSEMBLYC/O=TT = CTO = WC =

HEATERC/O=TT = CTO = WC =

FOAMING

13

Action PlanRPA n° Page : 1/1

Site : PDCA Methodology FAU-F-LS-0216/en - Issue 02

Creation date : Date revised:

N° CAUSE(S) ACTION(S) Resp. Deadline Done (date)

Checked (date) "Act"

1

2

3

Subject:

Leader: Area :

ACTION PLAN RECAP

PROBLEM

PDC

A PDC

A PDC

APDC

A

14

Kanban : Pull System

Assemblyline

B

b

Truck preparation

C

c

A

WK

Withdrawal Kanban loop

a

b

c

b

PIK

Production instruction Kanban loop

WK

WK

B

A

a

b

C

c

B

A

a

b

C

c

A

a

Supermarket

b