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Kaizen Blitz AR coating set up reduction-October 2005
The document outlines a Kaizen Blitz event focused on improving the AR room changeover processes from October 24-26, 2015. Key objectives included reducing changeover time, increasing productivity, improving safety, and enhancing training materials, with specific actions leading to significant time and cost savings. The process involved detailed phases for eliminating waste, adding personnel, and optimizing resources, resulting in a 68% reduction in cleaning time and substantial annual savings.
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Kaizen Blitz AR coating set up reduction-October 2005
- 1. Kaizen Blitz: ARRoom SMED Processes Sally Ulman & Alan Magner Mon-Wed 24th – 26th October, 2015 Contact: alanmagner@variancereduction.com
- 2. Agenda (see detailedagendas for each team) Monday Lean overview Measure current state Develop Action Item List Tuesday Complete Action Item List, new process map - Morning Map new process, document improvements, SOPs – Afternoon Wednesday Conduct new Change over - Morning Develop Presentation, Make Presentation @ 4pm
- 3. Leadership Support We empowerthe team to make process improvements Major changes will be reviewed and approved when possible Time, resources and equipment will be provided We hope most changes will occur DURING the event, all other action items will be given time to complete in the future
- 4. Kaizen Blitz Vision Faster,Better, We Help People See. Our aim for 2005 is to consistently deliver 48hr service to our Retail Customers from time of order to delivery back to store.
- 5. Scope of Activity 3- Day Kaizen Event focusing on AR Changeover to: Changeover time reduction Increased machine productivity, run time Improve cell organization Improve ergonomics & safety Clear SOPs & training materials
- 6. AR Setup ReductionKaizen Team Team “C.S.I.” Clean Syrus Improvement Team Members David Fairclough Ed Soriaga George Webster Facilitator: Alan Magner
- 7. No. of operstorsto do the task Skill level of operators Level on Cleanliness (scale 1 - 5) Amount of shields to change humidity in the room Machine Run time Sandblast machine - pressure Sandblast machine - quality of beads Machine downtime scotchbrite pads, chux wipes Product mix (ultra Vs Invisibles) Ease to clean (scale 1 - 5) sequence of shield changes Frequency of cleaning The INPUTS can be found by considering the 6 M's: Manpower Methods Machines Measurement Mother Nature Materials INPUTS OUTPUTS Shield cleaning on Syrus Process IPO – Syrus Clean
- 8. SMED Process Observe cleaningprocess, record times Eliminate wasted / unneeded steps Remove duplication of tasks Move steps from Internal to External of the set- up Simplify steps Improve safety at every opportunity
- 9. Action Item List Amountof actions listed 28 Actions taken 20 Actions outstanding 8 Completion Rate 71%
- 10. Phase 1 -Eliminate waste Breakdown of Phase 1 improvement Int. Time 57% Ext. Time 2% Eliminate 41% Total Time: 2h 30m 9s Time to eliminate: 1h 2m 18s Steps made external to set- up: 3m 45s Steps staying internal to set-up: 1h 24m 6s 43% reduction in set-up time
- 11. Total Internal Time 38% Timereduction with 2nd person 18% External Time 2% Eliminate 42% Phase 2 - Add 2nd person Total Time: 2h 30m 9s Time to eliminate: 1h 2m 18s Steps made external to set-up: 3m 45s Steps staying internal to set-up: 57m 32s 62% reduction in set-up time 2nd Person: 26m 34s
- 12. Total Internal Time 32% Timereduction with 2nd person 24% External Time 2% Eliminate 42% Phase 3 - Have extra shields Total Time: 2h 30m 9s Time to eliminate: 1h 2m 18s Steps made external to set- up: 3m 45s Steps staying internal to set-up: 47m 22s 68% reduction in set-up time 2nd Person: 36m 44s
- 13. 5S - ShieldTrolley Shields were stacked on top of each other Before After Every shield has a place
- 14. 5S - ShieldTrolley Before After
- 15. Visual Control: PreparationChecklist Have we everything we need? - easy to see
- 16. Sandblast machine Sandblast machine Trolley TrolleyTrolley for clean parts Trolley for dirty parts Dirty parts in Clean parts out Layout - Sandblast room Before - no clear workflow After - dedicated workflow
- 17. Safety improvement Hard toreach the V-1 - hazard Before After Safe access - using ladder Standing on/in machine parts to accomplish cleaning task Ladder now creates a safe work platform and no damage to machine parts
- 18. Error Proofing Best anglefor safe cleaning & preventing machine damage Visual - not locked in place
- 19. Error Proofing Cover toprevent damage to filament during cleaning
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- 21. Visual Controls •Each partstamped with a unique identifier number •Each number is also the sequence number for inserting the shields
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- 23. Track & Sustain Minutefor Syrus Clean 162 150 44 0 20 40 60 80 100 120 140 160 180 6-Oct 11-Oct 26-Oct 31-Oct 5-Nov 10-Nov 15-Nov 20-Nov 25-Nov 30-Nov 5-Dec Minutes Minute to clean Goal (60 mins) Stretch Goal (45 mins) 1st attempt at new procedure: 43m 40s
- 24. Set-Up Results Set-Up Timesfor Syrus Clean 2:30:09 1:24:06 0:57:32 0:47:22 0:00:00 0:30:00 1:00:00 1:30:00 2:00:00 2:30:00 3:00:00 Before Kaizen Removing Wasted Steps 2 People Extra Shields } Saved 1h 42m 47s per clean 68% reduction
- 25. $$ Savings AR Room: •2 Syrus coaters •Each are cleaned 6 times / month •Cleans / Year = 144 times •Hourly revenue = $900 (160 lenses @ 40mins) •Revenue = $15 per minute of downtime •Opportunity, every minute reduction in cleaning time results in an annual saving of $2160 per minute
- 26. $$ Savings Saved 1h 6m3s per clean 44% reduction Phase 1 Improvements : •eliminated waste and unnecessary steps $142,560 p.a. Saved 1h 32m 37s per clean 62% reduction Phase 2 Improvements : •Have 2 people do clean together $198,720 p.a.
- 27. $$ Savings Saved 1h 42m47s per clean 68% reduction Phase 3 Improvements : •Extra shields & parts $220,320 p.a.