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PD cell Kaizen event presentation


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PD cell Kaizen event presentation

  1. 1. Kaizen Event Assembly of Power Drive Units
  2. 2. Team Members Greg Williams and 7 other team members who shall remain nameless for this version of the presentation. Those chosen had considerable experience with the existing power drive manufacturing and assembly process and had some exposure to a previous Kaizen event
  3. 3. Previous state The team recorded: • Area = 80sq/m • Working environment was a small area in the aisle between assembly benches and racking. • Limited access for forklift into racking when assembling Power Drives. • Walking distances 650 metres per PD x 2.5 PD a day = 1.62km per day • No of operators = 4 required by ST point scheduling • Cycle time = 260min
  4. 4. Previous state Packing crates as benches, cubicles stored on floor Components difficult to access Components strewn in various non-defined locations. Batching of assemblies
  5. 5. Previous state Recorded times were transferred to bar charts Version 3 - New two operator sequencing Version 3 with a further 30 minute reduction in cycle time. Now 135 minutes. Further reductions were expected by reduced walking times with new cell layout
  6. 6. Previous state Parts retrieval spaghetti chart Previous state 650 mtrs walked for each Power Drive assembled equated to 1.62klms per day
  7. 7. Version 4 - New two operator sequencing NOTE: Further reductions expected by reduced walking times with new cell layout. Recording of new times still required to show 15 minute reduction in cycle time. The target of 4 Power Drives a day was achieved.
  8. 8. Cell design • The team used a combination work chart to: – Reduce cycle time – Decide the correct sequence of standard work – Synchronise sub assembly and main assembly operations • Decide on U shaped counterclockwise cell layout • Right sized part racks and buckets within easy reach • Modified jigs and fixtures • Dedicated pedestal and bench drills for eliminating jig setup times • Lift trolleys for one piece flow assembly providing easier access and manipulation of assemblies • Fastener and tool trolleys • Crane for ease of lifting into cabinet and crates
  9. 9. White board was installed for operators and management walk around to track progress
  10. 10. Dedicated drills to eliminate jig setup times Dedicated tool and fastener trolleys Component buckets positioned for ease of access Adjustable trolley heights reduced operator movement when accessing heavy parts
  11. 11. Result of New Cell Design 4 Complete main mech assy 3 Drill motor and auxy switch 2 Start main mech assy 1 Drill gearbox 8 Pack 7 Install main assy into cubicle 6 Prepare cubicle 5 Electrics installed overnight
  12. 12. Results Before After Improvement Area 80sq/m 61sq/m 24% reduction Cycle time 260min 135min 48% reduction Crew size 2 req normal scheduling 4 req for EA schedule planning 3 in training Target of 2 25% reduction in ST planned crew size Target is 50% crew size reduction WIP = = None Inventory = = None Productivity 12 PDs per week 20 PDs per week 66% increase
  13. 13. To Do • Further gains are anticipated through investigation of the following: – Shaft and stop design to remove welding process – Chain cut to length by subcontractor – Breather gauze and foam cut by subcontractor – Din rail cutter which has been implemented already – Wire handle cap retaining chain made outside – Crane required – Sharing with Ergon cell at present – Supply and install of the wiring loom. This is essentially our drum beat. – Hand over to continuous improvement team/cell operators – Cell operators have already listed various other improvements on their whiteboard