1. Cook top Rework KaizenCook top Rework Kaizen
Objective D-Stock ReductionObjective D-Stock Reduction
MembersMembers
Randy BronsRandy Brons
Debora GloverDebora Glover
Rapheal DunnRapheal Dunn
James TaylorJames Taylor
Donna BundyDonna Bundy
Timothy BurwellTimothy Burwell
2. Rework Production BoardRework Production Board
INFORMATIONINFORMATION LowLow
RunnersRunners
GASGAS GASGAS ELECTRICELECTRIC ELECTRICELECTRIC
Production
Schedule
Raw On Hand Part No. Description Cost center Net Req.
150309
13:00:00
150309
14:00:00
150309
15:00:00
150309
16:00:00
150309
17:00:00
150309
18:00:00
150309
19:00:00
150309
20:00:00
150309
21:00:00
150309
22:00:00
150309
23:00:00
150309
24:00:00
150310
00:00:00
150310
01:00:00
150310
02:00:00
150310
03:00:00
150310
04:00:00
150310
05:00:00
150310
06:00:00
150310
07:00:00
150310
08:00:00
150310
09:00:00
150310
10:00:00
150310
11:00:00
150310
12:00:00
150310
13:00:00
316202370 35 316202371 MAINTOP-PANEL GAS SB28 BLK 140142001 -300
316202386 368 316202387 MAINTOP-PANEL BLK UP COIL 2+2 140142001 -1508 268 134 134 134 134 268
316202386 56 316202388 MAINTOP-PANEL UP WHT E 2+2 140142001 -1218 134 134 268 134 134
316245400 538 316245402 MAINTOP-PANEL SLAB WHT E 2+2 140142001 -467 134 134 134 201
316245400 162 316245404 MAINTOP-PANEL SLAB BLK E 2+2 140142001 28 134
316245401 84 316245406 MAINTOP-PANEL SLAB WHT E 3+1 140142001
316254500 324 316254501 MAINTOP-PANEL BLK GAS SB30 140142001 -658 132 134 134 2 132 134 134 2
316254500 73 316254502 MAINTOP-PANEL WHTGAS SB30 140142001
189 316273001 MAINTOP-PANEL SL OPN V SQR WHI 140142001 -933 255 2 132 134 2 132 24
58 316273002 . 140142001 -144 132 70
316469652 115 316469653 MAINTOP-PANEL BLK DS 5 BURNER 140142001 18 97
316469652 143 316469654 MAINTOP-PANEL WHTDS 5 BURNER 140142001 9 134
316610005 MAINTOP-PANEL WHTGAS SB57 140142001
20 316610006 MAINTOP-PANEL BLK GAS SB57 140142001 -105
316610008 42 316610009 MAINTOP-PANEL WHTSB54 W/BRKT 140142001 -124 132 34
316610008 68 316610010 MAINTOP-PANEL BLK SB54 W/BRKT 140142001 -108 132 44
28 316610013 MAINTOP-PANEL WHTDS 5 BURNER 140142001 -118
52 316610014 MAINTOP-PANEL BLK DS 5 BURNER 140142001 -1180 136 134 134 134 134 134 134 134
31 316610015 MAINTOP-PANEL BIS G SB56 ENMEL 140142001 -41
316610020 316610022 MAINTOP-PANEL BLK GAS SB 140142001 -233 31 31 27 31 31 10 31 31 10
125 316610037 MAINTOP-PANEL UP WHT 2+2 BRKT 140142001 -1271 67 67 327 209 134 134
1511 316610038 MAINTOP-PANEL BLK UP COIL 2+2 140142001 1176 67
40 316610039 MAINTOP-PANEL UP BIS COIL 2+2 140142001 -27
316610052 56 316610053 MAINTOP-PANEL WHTG SB31 ENMEL 140142001 -212
316610052 81 316610054 MAINTOP-PANEL BLK G SB31 ENMEL 140142001 16
152 316610061 MAINTOP-PANEL GAS WHT W/BRKT 140142001 -75
40 316610062 MAINTOP-PANEL GAS BLK W/BRKT 140142001 -528
40 316610063 MAINTOP-PANEL GAS BIS W/BRKT 140142001 -35
Production Schedule
Color Part # # of Boxes Quantity Time to Hang Comments
WHT 2370 4 124 11.3
BIS 10036 6 216 19.6
BLK 10008 8 288 26.2
10036 2 72 6.5
10032 6 216 19.6
4500 2 62 5.6
10032 6 216 19.6
WHT 10036 6 216 19.6
10032 6 216 19.6
2370 3 93 8.5
10032 6 216 19.6
BLK 4500 6 186 16.9
10032 5 180 16.4
4500 6 186 16.9
10032 5 180 16.4
WHT 10036 10 360 32.7
2394 2 62 5.6
10036 2 72 6.5
3000 5 250 22.7
ONLY CLEAR PART # AND BOX QTY DO NOT SAVE
Daily Cooktop Order Sheet Date_______ Shift _____
On Line Setup
Part Number 5 Day On Hand Des cription MCU 03/13/15 03/14/15 03/15/15 03/16/15 03/17/15
316202371 252 MAINTOP-PA NEL GAS SB28 BLK 140142001 126 126
316202372 546 MAINTOP-PA NEL GAS SB28 WHT 140142001 546
316202387 3,175 MAINTOP-PA NEL BLK UP COIL 2+2 140142001 4 756 1218 1197
316202388 3,066 MAINTOP-PA NEL UP WHT E 2+2 140142001 756 1176 1134
316245402 1,638 MAINTOP-PA NEL SLAB WHT E 2+2 140142001 378 630 630
316245404 0 MAINTOP-PA NEL SLAB BLK E 2+2 140142001
316245405 0 MAINTOP-PA NEL SLAB BIS E 2+2 140142001
316245406 0 MAINTOP-PA NEL SLAB WHT E 3+1 140142001
316245408 0 MAINTOP-PA NEL SLAB BLK E 3+1 140142001
316245409 0 MAINTOP-PA NEL SLAB BIS E 3+1 140142001
316254501 1,622 MAINTOP-PA NEL BLK GA S SB30 140142001 488 378 756
316254502 0 MAINTOP-PA NEL WHT GAS SB30 140142001
316254505 189 MAINTOP-PA NEL BLK GA S SB31 140142001 126 63
316254506 378 MAINTOP-PA NEL WHT GAS SB31 140142001 252 126
316254507 0 MAINTOP-PA NEL BIS GAS SB31 140142001
316273001 1,010 MAINTOP-PA NEL SL OPN V SQR WHI 140142001 2 252 252 504
316273002 195 MAINTOP-PA NEL SL OPN V SQR BLK 140142001 69 126
316273003 126 MAINTOP-PA NEL SL OPN V SQR BIS 140142001 126
316469645 588 MAINTOP-PA NEL BLK DS 5 BURNER 140142001 252 336
316469605 0 MAINTOP-PA NEL BLK DS 5 BURNER 140142001
316469653 504 MAINTOP-PA NEL BLK DS 5 BURNER 140142001 504
316610010 673 MAINTOP-PA NEL BLK SB54 W/BRKT 140142001 673
316469661 0 MAINTOP-PA NEL BLK DS 5 BURNER 140142001
316469662 0 MAINTOP-PA NEL WHT DS 5 BURNER 140142001
316610005 0 MAINTOP-PA NEL WHT GAS SB57 140142001
316610006 264 MAINTOP-PA NEL BLK GA S SB57 140142001 144 120
316610009 122 MAINTOP-PA NEL WHT SB54 W /BRKT 140142001 122
316610013 10 MAINTOP-PA NEL WHT DS 5 BURNER 140142001 10
316610014 2,533 MAINTOP-PA NEL BLK DS 5 BURNER 140142001 3 919 504 1107
316610015 8 MAINTOP-PA NEL BIS G SB56 ENMEL 140142001 8
316610022 165 MAINTOP-PA NEL BLK GA S SB 140142001 2 163
316610037 882 MAINTOP-PA NEL UP WHT 2+2 BRKT 140142001 252 630
316610038 340 MAINTOP-PA NEL BLK UP COIL 2+2 140142001 340
316610039 0 MAINTOP-PA NEL UP BIS COIL 2+2 140142001
316610053 0 MAINTOP-PA NEL WHT G SB31 ENM EL 140142001
316610054 0 MAINTOP-PA NEL BLK G SB31 ENMEL 140142001
316610061 126 MAINTOP-PA NEL GAS WHT W/BRKT 140142001 126
316610062 345 MAINTOP-PA NEL GAS BLK W/BRKT 140142001 345
316610063 0 MAINTOP-PA NEL GAS BIS W/BRKT 140142001
5 Day Schedule
3. REWORK JDS Changes to JDS
1: Do and audit of rework staging
2: Rework TM will run to production schedule
3:Rework TM will rework to on-line setup
4. TOWMOTOR
TTOWMOTOR Changes to JDS
1: Driver will adjust on-line setup
per available rework.
2: Driver will take all empty RRC’
to designated locations.
5. Ticket Writer
Change to JDS
1:TM will consolidate all partial carriers
in D-stock
2: Tm will setup all partials per on-line
setup coming off unload.
3: TM will fill out red tag with product on
rework carrier
7. Process ReworkProcess Rework
1: Cook top rework Team member verifies rework staging is accurate to1: Cook top rework Team member verifies rework staging is accurate to
rework board.rework board.
2: Cook top rework team member will run off online setup from previous2: Cook top rework team member will run off online setup from previous
shift till new schedules and online setups are delivered.shift till new schedules and online setups are delivered.
3: Cook top rework Tm will rework tops needed for schedule per online3: Cook top rework Tm will rework tops needed for schedule per online
setup and stage tops to be hung at end of raw tops.setup and stage tops to be hung at end of raw tops.
4: When there are no tops to rework per online setup TM will rework tops4: When there are no tops to rework per online setup TM will rework tops
per 5 day schedule or work on low runners.per 5 day schedule or work on low runners.
5: Cook top rework TM will get all red tickets from returns for assembly5: Cook top rework TM will get all red tickets from returns for assembly
and unload and update rework board as the returns come in.and unload and update rework board as the returns come in.
8. Process Unload Team leaderProcess Unload Team leader
1: TL does full wall count of all finished cook tops in assembly, staging1: TL does full wall count of all finished cook tops in assembly, staging
and D-stock.and D-stock.
2: Takes counts to finishing office to put counts in Finishing schedule2: Takes counts to finishing office to put counts in Finishing schedule
spreadsheet.spreadsheet.
3: Schedules are printed out and distributed to Unload TL, Load TL, and3: Schedules are printed out and distributed to Unload TL, Load TL, and
Cook top rework team member.Cook top rework team member.
4: Unload TL does online setup for 8 hrs production and enters in to setup4: Unload TL does online setup for 8 hrs production and enters in to setup
spreadsheet on computer and distributes to ticket writer, Cook top reworkspreadsheet on computer and distributes to ticket writer, Cook top rework
and a copy at unload TL desk.and a copy at unload TL desk.
5: Unload TL communicate to load driver, and will hang raw tops and5: Unload TL communicate to load driver, and will hang raw tops and
adjust online schedule per rework ready amount.adjust online schedule per rework ready amount.
6: Unload TL will factor in all fallout and adjust for customer demands.6: Unload TL will factor in all fallout and adjust for customer demands.
9. Process Ticket Writer
1: Will receive copy of D-stock counts and online setup schedules.
2: Will consolidate all partials in the D-stock area.
3: Will setup any partial carriers as needed with online setup of finished
product coming off at unload.
4: Will manage D-stock to keep area clean and neat with one single row
of finished product.
10. Process Towmotor Driver Load
1: Communicate with Unload TL of changes to online setup per amount
of rework being hang.
2: Put all Empty RRC’s in proper locations, SSI empties in new cooktop
line, Grenada empties on trailer and empties from manual cooktop
in raw cooktop D-stock in empty location.
11. Conclusion Kaizen Project
1: By utilizing this process it will lower the over runs in D-stock.
2: The process is setup to run the rework needed for customer demand.
3: The process will give a better flow of parts coming off at unload.
4: The process will minimize partials carriers in the D-stock area.
5: The rework will be better maintained with locations for rework ready
and rework to be done.
6: Using this process we will be using the product needed not just hanging
rework and storing on partial carriers at unload D-stock.
Base Line : Reduce D-Stock from 64 Carriers 1st
week reduction of 16
carriers, 2nd
week 16 carriers.
Communication Will Be The Key
12. Supplies needed
1: 5x5 Magnetic Board
2: Paint 2 Gal. Yellow, Green , White and Sealer
3: Rails 2 will get WO. For maintenance
4: 4 Visual factory signs,
1 Low runner
1 Rework to be hung
1 Rejects for Cook top unload
1 Transfer rejects
