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Kaizen Blitz multicoat loading area April 2005

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Kaizen Blitz: AR Room SMED Processes
Sally Ulman & Alan Magner
Monday 11th – 15th April, 2005
Contact:
alanmagner@variance...

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Kaizen Blitz MultiCoat Load Area
Team Members (l-r)
Sally Ulman
Josie
Anita
Lira
Alan Magner
George Webster
Ida
Justino
Ju...

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Event Goals
Reduce Lead Time
Current Lead Time = 1099 minutes.
Goal = 60 minutes (94% reduction)
Cycle Time
Current Cycle ...

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Kaizen Blitz multicoat loading area April 2005

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5 - Day Kaizen Event focusing on AR Changeover to:
- Lead time reduction
- Cycle time reduction
- Improve workflow
- WIP reduction
- Improve ergonomics, housekeeping & safety
- Clear SOPs & training materials

Achieved
- 81% Lead time reduction
- 37% Cycle time reduction
- 80% WIP reduction

5 - Day Kaizen Event focusing on AR Changeover to:
- Lead time reduction
- Cycle time reduction
- Improve workflow
- WIP reduction
- Improve ergonomics, housekeeping & safety
- Clear SOPs & training materials

Achieved
- 81% Lead time reduction
- 37% Cycle time reduction
- 80% WIP reduction

More Related Content

Kaizen Blitz multicoat loading area April 2005

  1. 1. Kaizen Blitz: AR Room SMED Processes Sally Ulman & Alan Magner Monday 11th – 15th April, 2005 Contact: alanmagner@variancereduction.com
  2. 2. Kaizen Blitz MultiCoat Load Area Team Members (l-r) Sally Ulman Josie Anita Lira Alan Magner George Webster Ida Justino Julie
  3. 3. Event Goals Reduce Lead Time Current Lead Time = 1099 minutes. Goal = 60 minutes (94% reduction) Cycle Time Current Cycle time = 863 seconds Goal = 777 seconds (10% reduction) WIP Current WIP – 548 jobs Goal = 100 jobs (82% reduction) Travelling Distance Current = Poly – 13.8 metres, CR39 – 16.9 metres, CR39 + tint – 21.1 metres Goal = Poly – 7 metres, CR39 – 8.5 metres, CR39 + tint – 10 metres Improve the appearance of the line Improve the working conditions of the line These two items will go to improve morale and make the work area clean and safer
  4. 4. MultiCoat Loading Area Operation Input Process Output Diagram Outputs Lead time (minutes) Cycle time (seconds) WIP (jobs) Travelling distance (metres) Cell organization (1-5) Workflow from Grind Methods & SOPs Room Layout Labour Utilization Consumables & Equipment (racks, clips, wipes) Inputs Goal
  5. 5. Leadership Support We empower the 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
  6. 6. 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.
  7. 7. Sub Teams Layout Team: George, Lira, Julie - Layout Alan, Anita, Josie – Repetitious work 5S, Visual Controls Sally, Justino, Ida
  8. 8. Agenda DATE TIME FRAME TIME AGENDA Monday, 11-April-2005 9am - 5pm AM Leadership debrief, Goals, training 12:00 - 1:00pm PM Debrief & working lunch (Training Room) 1pm PM 5s/Visual Control Team: Action Items Layout Team, Map Review, Repetitious work study Tuesday, 12-April-2005 9am - 5pm AM 5s/Visual Control Team  Action Items Layout Team: options for new layout Repetitious Team: Time observations, cycles of 7, options for best practices 12:00 - 1:00pm PM Debrief & working lunch (Training Room) PM 5s/Visual Control Team  Work Action Items Layout Team: Determine best layout option 4pm Give a debrief to Leadership Wednesday, 13-April-2005 12:00 - 5:00:pm PM Layout Team: Prepare for new layout 12:00 - 5:00:pm PM 5S Team: Complete action items at individual work stations 5:00 - 6:00 pm PM Debrief & working lunch (Training Room) 6:00pm - 12:00am PM All teams organise new layout and work stations Thursday, 14-April-2005 6am - 9am AM Instruction on new layout from Layout Team Representative 10am - 12pm AM All Teams: Monitor & modify new layout 12:00 - 1:00pm Debrief & working lunch (Training Room) 1pm - 2pm PM 5S Team: Modifies workstations 1pm - 2pm PM Layout Team: Time new workflows 2-4pm PM Instruction on new layout from Layout Team Representative 4pm - 5pm PM 5S Team: Modifies workstations 4pm - 5pm PM Layout Team: Time new workflows Friday, 15-April-2005 6am -6:30am AM Instruction on latest updates from Layout Team Representative 9am - 10:30am AM All Teams: Finalise presentation 10:30am AM Make presentation to Leadership 12pm PM Celebrate achievements & lunch at Lone Star
  9. 9. Layout Team Team Members George Julie Lira
  10. 10. Layout Team Repetitious Work SOPs, New Layout Draw up action items list Revise existing flow map New SOPs for repetitious work Key aspects of new layout Determine gaps in current system New work process cycle times New lead times with new layout Potential Layouts, and prioritize selection
  11. 11. Objectives of Flow Reduce work in progress (WIP) Eliminate unnecessary travelling Eliminate unneeded separation of work Cost to Implement Easier access to conveyors for loading staff Allow for better flow of tinting jobs Reduce lead time Balance the line
  12. 12. Layout #1
  13. 13. Layout #2
  14. 14. Layout #3
  15. 15. Layout #4
  16. 16. Layout Design Matrix Layout #1 Layout #2 Layout #3 Objectives of Layouts 3 1 2 3 1 4 1 2 4 4 3 13 4 1 1 3 2 3 4 1 19 22 16 Layout #4 2 2 4 2 4 2 3 2 3 1 4 23 The Kaizen voting results are listed above. It was felt that #2 and #4 were tied. The management team voted to break the tie and #2 was chosen!
  17. 17. Current Layout
  18. 18. The Move
  19. 19. New Work Stations
  20. 20. Finalized Layout
  21. 21. Layout Team Achievements Clearer lines for product flow Improved visibility in department Completed tint jobs flow to sorting No more walking for loaders!! Now have room to expand capacity Visual controls for WIP using Kanbans Lighting improved at workstations
  22. 22. Layout Team – Repetitious Work Team Members Alan Josie Anita
  23. 23. Repetitious Work – Layout Team Every person had a different technique for Wearing gloves or not Cloths they were using Lens cleaning and Loading These were actioned itemed, as were; Workflows with kanbans Handling rejects Error-proofing and timings
  24. 24. Different Wipes and Glove, No Glove
  25. 25. Glove, No Glove New SOP on wearing gloves: Team members on lens cleaning and lens loading to wear a pair of Nitrile gloves – to protect wearer from sharp edges and exposure to methnol, and to protect the lens from fingerprints and markings
  26. 26. Different Wipes
  27. 27. Different Wipes Decided to use 1 type of cleaning cloth only – the Blue Chicopee wipes. All white cloths were removed from all work areas. An action item list is to test 4 possible cloths; based on performance and cost.
  28. 28. Proper Cleaning Methods Correct gloves and cleaning towel
  29. 29. Work Stations Before
  30. 30. WIP Removed Work In Progress before, later the work was processed and many of the racks were removed for the final layout
  31. 31. Old way of Loading of #3 Jobs - CR
  32. 32. Proper Loading of #8 Jobs The first space is empty All clip hangers are correctly in the grove above The #8 clip is used Equal spacing can be seen on the bottom at each clip
  33. 33. Proper Loading of #9 Jobs
  34. 34. Process Book Number Process Book Number Completed Process Book Number
  35. 35. How Racks Might Come from Cleaning Area Here, the clips are in the closed position. Having them like this will prevent them getting hooked up Here, the clips are in the open position, the arms can get tangled when removing them to load the clip.
  36. 36. Jig or No Jig, That is the Question In January the jig was used by most people. Notice the failure rate downstream in sample one of Test of Proportions (n1). In April, very few used the jig. Notice the failure rate downstream in sample one of Test of Proportions (n2). Conclusion: using the jig does not appear to have an impact on downstream failures. But ….. Does the jig reduce cycle time? User defined parameters Number Defective Group #1 (x1) 55 Size of Sample #1 (n1) 8500 Number Defective Group #2 (x2) 52 Size of Sample #2 (n2) 9500 Proportion Sample #1 (p1) 0.00647 Proportion Sample #2 (p2) 0.00547 p-value 0.38506 Test of Proportions Results SPC XL is Copyright (C) 1999 Digital Computations, Inc. and Air Academy Associates, LLC. All Rights Reserved. Unauthorized duplication prohibited by law.
  37. 37. Jig Test – 12 Lenses in Each Test Jig Use Finding: Cycle Time = 1:57 Rework = 0 Observations: • Good • Less likely to scratch lens • Sat securely • Did not look hard to do No Jig Use Findings: Cycle Time = 1:16 Rework = 1 Observations: • Ida had a great technique • Looks more difficult to new workers, both to do and in scratching lens • Might be tilted Final Decision: Jig. We will adopt an SOP that address the non-jig people To make using the jig the best it can be.
  38. 38. Proper Jig Use Proper use of the jig Note how long the clip goes down into the jig The clip arms are in the wheels each side of the jig The arms will open and the lens can be easily placed in the correct position
  39. 39. Proper Loading of Clip on Jig Sometimes loaders would allow The clip arms to twist when loading Clip arm has to be is the groove of the wheel If the clip arms are flat against the back of the jig the arms WILL go in the wheel groves
  40. 40. Error Proofing of Jig Adding a space on the top of the jig allows for the top of the clip to be braced during the loading of the clip The side view shows the thickness of this spacer.
  41. 41. Another Error Proofing of the Jig To ensure the proper placement of a FT in the clip, lines were drawn on the jig. If the operator lines up the top of the FT to the lines, either over them or parallel to them, it will be at the correct 300 angle
  42. 42. Proper Loading of Lenses on Holders To load property the narrow end of uneven lenses need to be on the bottom, the wide area on the side
  43. 43. 65 and CR Clips Clip used to 65 size lenses. Note the Yellow Color at top Clip for CR, note the blue color at the top
  44. 44. Poly Clip This is a Poly Clip Note there is no color at the top of the clip.
  45. 45. 5S / Visual Controls Team Team Members: Sally Ida Justino
  46. 46. 5S, Visual Controls Action items list Before and After pictures Goals of the group Determine gaps in current system
  47. 47. 5S, Visual Controls Goals To set the standard for workplace organisation Implement procedures to ensure consistency Positively effecting workplace safety, product quality, production cycle times and capacity Supporting Visual Factory Management will develop the model cell for the rest of the plant to benchmark All this will be achieved by using the most simplistic methods possible interviewing all involved in the set-up and ultimate decisions.
  48. 48. 5S, Visual Controls Team Action Items Kaizen Blitz – Action Item – Multicoat 5S Team Number Priority # Problem/Need Solution/Action Person Responsible Date Due Date Done 1. Incoming lenses on floor, no clear marking where they should be Set in order – mark it. Justino 15 April 13 April 2. Scanner and mouse in incoming area, no home Set in order – mark it Justino 15 April 13 April 3. Scan cards not colour coded for type Colour code Ida 30 April 4. No area for scanned item Set in order – mark it Justino 15 April 13 April 5. Lack of organization of yellow cleaning area 5S the area Ida – moved to grind dept 15 April 13 April 6. No clear direction of where trays go Flow pattern with arrows are needed Justino 15 April 13 April 7. Lack of organization in cabinet under yellow marking area 5S the area Ida 15 April 13 April 8. Lack of organization of the equipment and materials in the tinting area 5S Ida 15 April 13 April 9. Bad access for loaders to get jobs Better layout to minimize motion and transportation Justino 15 April 13 April 10. Load bench disorganized. No set standard Set in order – 5S Justino 15 April 13 April 11. Disorganized supervisors office and MSDS binder area Set in order, 5S Justino 15 May 13 April 12. Loading scanner, no easy access Better layout Ida – Layout Team 15 April 14 April 13. Storage area shelving is large and has wrong labels – they are outdated Decide needed space requirements, Set in order – 5S Ida 15 April 13 April
  49. 49. 14. Mouse and scanner at load area has no real home Needs a home – layout and 5S Ida - Layout 15 April 14 April 15. After loading, no clear direction to conveyor Flow pattern with arrows are needed Justino 15 April 13 April 16. Notice board is outdated Determine what items are needed on the board and place it is an area where it will be seen. Ida 15 April 14 April 17. Clean holders are not easily accessible and are just dumped into the bins Find a good place for them, store them in a better orientation for loading – develop best method Ida 30 April 18. Lack of posted, visual SOPs in loading area Develop SOPs with visual controls shown Justino 15 April 13 April 19. Lack of posted, visual SOPs in tinting area Develop SOPs with visual controls shown Ida 15 April 13 April 20. SOPs in incoming sort area need to be placed on top of rack Get holders that grind uses to place them in Justino 20 April 21. Extra clips when holder racks are not full have no home at the loading station Need a home, set up a bin and location Ida 14 April 14 April 22. No home for rejects at loading station Need a home, set up a bin and location Justino 14 April 14 April 23. No home for 65 clips at the loader station Need a home, set up a bin and location Ida 14 April 14 April 24. Trash cans under cleaning area are unstable Get engr to secure better and a better spacer Justino 14 April 14 April 25. No stapler at the sorting table Find a stapler and a home for one at the sorting table Ida 14 April 14 April 26. 5S, Visual Controls Team Action Items
  50. 50. Incoming Area Before Picture Work on the floor, tripping hazard, too much WIP. After Picture Limited amount of work is stored in the incoming racks, all are sorted before going to the loaders
  51. 51. Dipping Waste and Throughput Board Before Picture After Picture, this is located in an area better seen by the workers
  52. 52. Boards in the Area Before Picture Clutter on boards. Not standardized. Needs to be In the best place for all to see. 5S the boards, place in a good spot with just the info we need on it.
  53. 53. The Area has Signage with Clear Goals for All Involved You are entering a Set – In – Order Zone Area Goals
  54. 54. Yellow Line Removal Before: Small area to work, items for process have no clear home SOPs covered by all the WIP!
  55. 55. Inlet Rack to Load Area Before Picture Too much WIP, not clear on prioritized work, flow is impeded, difficult for loaders to access.
  56. 56. The New Layout has a Major Reduction of WIP Only this side of the inlet trays have lenses, the other side are empty trays for recycle to grind A small number of lenses will be in queue in tinting A limit of 6 trays are to be at each of the 2 stations.
  57. 57. Tint Area - Before Before Picture No clear direction of flow, too much stuff, disorganized stuff on the floor, no clear SOPs.
  58. 58. Tint Area After
  59. 59. Tint Samples Before - these racks were in the wrong order, could fall down, and added clutter to the area After - the racks are numbered, in the Right order and mounted In the packets they came in.
  60. 60. Misc. Stuff Before Before Picture Inconsistency in where items are placed. Need 5S!
  61. 61. Load Work Station at Shift Start - Before Before Picture Inconsistency in the work stations. They look really clean at the start of Each shift, but take on a different look when works starts. Need to perform 5S and standardized work station layout and procedures. Two Different Work Stations Load Area
  62. 62. Materials used at Cleaner and Loading Station Methanol and wipes for cleaning Rack tags and rubber bands to tie up the grind cards
  63. 63. Load Station Before Methanol container is to the upper left and operator is right handed, this increases the stretch. Before Picture This work station looks different from others. Need 5S and standardized work stations.
  64. 64. Load Station Before and After Before Picture Jig is not used in this work station This workstation looks different from others. Need 5S and standardized stations. After Picture All items in the station are used on a daily basis, are in places designed by line workers
  65. 65. Loading Scanner Location Before Picture No place for the scanner and mouse, no table to place products to scan them AND see the monitor at the same time.
  66. 66. Handling rejects No clear procedure for dealing with lenses that have scratches: Most people place in a tray, the under the desk, and chase Supervisor for a 2nd opinion Now have a central point for any defect lenses found at loading – Supervisor knows where to look for any problem jobs Before Picture After Picture
  67. 67. Clips / Lens Holders Before Picture Different holder types Holders are stored in a haphazard manner from cleaning process in the bins
  68. 68. Materials Storage Area Before Picture Holder bins and marks in the storage cabinet. Needs 5S and visual controls that can be seen and used.
  69. 69. Supervisor Station Before Picture Supervisors station is full of clutter and easy access to the MSDS books. Area needs to have 5S done and only the items needed in the area.
  70. 70. Supervisor Station After Justino is performing 5S in the desk Area, making a place for everything. Final work, everything here is NEEDED. has a home and is in it’s home.
  71. 71. Conveyor and Extra Storage Before Picture Remove the board where it is needed, if it is needed. Might use just the SOPs on the board. Extra storage area might need to be moved or removed. 5S will sort this item, placing it in the Red Ticket area, if layout wants it, we can bring it back.
  72. 72. Marking the Conveyor Before, it was not clear where to place racks on the conveyor. After, the GREEN area shows where The racks are to be placed.
  73. 73. Cleaning of lenses SOPs not given importance in old layout In new layout SOPs are given more visibility
  74. 74. Workflow is now obvious No clear workflow, lots of unnecessary motion New SOPs use as little motion as possible, influencing the new desk layout
  75. 75. Set up Kanbans for all workflow Empty trays CR 39 Poly Set up Kanban of 6 trays for Grind to Multicoat job sorting Set up Kanban of 3 trays from Job sorting to loading Set up a “Pick me Next” identifier to preserve FIFO workflow
  76. 76. New 1-page photo-rich SOPs
  77. 77. Kaizen Achievements Reduce Lead Time Past state Lead Time = 1099 minutes. Goal = 60 minutes (94% reduction) Achieved = 131 minutes (88.1% reduction) Cycle Time Past state Cycle time = 863 seconds Goal = 777 seconds (10% reduction) Achieved = 538 seconds (37.7% reduction) WIP Past state WIP – 548 jobs Goal = 100 jobs (82% reduction) Achieved = 269 jobs (50.9% reduction) Travelling Distance Past state = Poly – 13.8 metres, CR39 – 16.9 metres, CR39 + tint – 21.1 metres Goal = Poly – 7 metres, CR39 – 8.5 metres, CR39 + tint – 10 metres Achieved = Poly – 11.8 metres, CR39 – 11.4 metres, CR39 + tint – 16.6 metres Improvement = Poly 14.5% CR39 32.5% CR39 + tint 21.3%
  78. 78. How the Kaizen Team Feels Sustainability will be Accomplished Communicate with members consistently Positive encouragement Lead by example Keep explaining! Collect feedback – promise to review in 2 weeks time (allow time for acceptance) Spot checks! – by the Supervisor 1-to-1 training on new technique; for the first week, give refresher training daily
  79. 79. Next Steps – Wish List Place two more tables in the loading area, making it possible to add 2 people to the area to process more product, IF NEEDED Extend the conveyor down to the 2 new tables 5S the cleaning of clips area since our work cell members work in their as well – another Kaizen might be needed to do this Install an LCD display board for Lenses per hour per person
  80. 80. This Says It All

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