Tanner Orban

Tanner Orban University Of ToledoUndergraduate in Mechanical Engineering

Safety is the #1 priority

Plan

Review JSRAs/Write Kaizens

Plan

DO

Submit Planned WOs, Create OPLs, Update AM Calendars

Check

ACTAreas of extension in the dept.Taylor WindfieldNorth WeldexSouth WeldexPack offMeritechsBondcell

Results15 high risks reduced to 0 = 100% reduction in HIGH risks.3 quick and 5 standard kaizens written.73 Total risk reduction points across the dept. Step 3 completed and moved into step 4.

ResultsElimination of hazard that created an FAI in 9850.

Eliminating Non-Value Activities

Why are we here?

HIGH NVAA IN 9855 MANUAL BUILD LINE #2What does the problem look like?

Lets see

Why do we pack the same parts in two different ways???Multiple skids every hourManually handling parts constantly.

PLAN

Final build counts for Manual build #2

DO

OUTLIERSFor the first three weeks of June: 1st shift averaged 1100 and 2nd shift averaged 1092!

With the proposed packing method, the operator does not have to make this flip before the cover is placed on the piston.

This method takes 3 seconds to complete and is less of an ergonomic strain on the operator.

CHECK

ACT

This project idea was read across to Dept. 9821 on three different lines to eliminate 3 level 2 Muris and account for $14,518.00 savings.

ACT

Eliminate Micro-stops

GembaGo to the operation

GembutsuTalk to the operators and floor workers. GenjitsuCollect and analyze data to apply countermeasures. GenriDetermine root cause.GensokuStandardize and read across to other areas. 5 Gs

5 Whys?Problem: Based on CD 11 op 50 pivot bracket welder has been charged with $254,000 of micro-stoppages.Why?: The pivot welder has numerous faults per shift. Why?: The inner jacket bore faults out many times a day which causes the pivot welder to fault out. Why?: Gantry #1 accounts for over 50% of all inner jacket bore faults.Why?: The sensors were dirty, the grippers were low on air pressure and the in feed conveyor was out of synchronization with the inner bore. Why?: Lack of specific AM, programing software was not adjusted when inner bore was worked on resulting in faulty communication between the two machines.

Currently this project is in step 5 of the 7 steps of micro stop elimination. We are checking our effective countermeasures thus far. A team is in place to identify the root causes for the remaining 50% of micro stops at this machine. This project was chosen as one of 9 to be shown in the WCM audit and is projected to save over $200,000.

Where we are headed

Current Projects 9826 Micro stop project with Straddle Mill. (Check phase)9826 project with AM cleaning. (Do phase)9826 JSRA reductions plan for step 4. 9853 Silo project. (Do phase)

Summary Closed project savings73 JSRA points reduced5 level 2 Muri risks eliminated. $38,111.759854 up a safety step

Open projects savings$232,86739 JSRA points3 level 1 Muri Risks9826 up a safety step

Valuable real world training and experience!!