1. Reducing Bottling Lines
Downtime at
LeVecke Corporation
Ismael Reyes
SGB 110 -2016

2. Define-Project Charter

3. Define- SIPOC
S I P O C
• Tank Room
• Receiving Department
• Shipping Department
• Liquid/Product
• Dry Components
• Pallets
• Finished Case Goods
• Pallets
• Warehouse
• Shipping Department
Request for
Components Rotate
Request for
QC Check
Bottle
Accordingly
to Plan
Clean
• Repeat as necessary depending
on production schedule

4. Measure
2.60
1.68
0.88
0.78
0.42
0.32
0.00 0.00 0.00 0.00 0.00 0.00 0.00
11
7
13
4
1
2
0
1
0 0 0 0 0 0
2
4
6
8
10
12
14
0.0
0.5
1.0
1.5
2.0
2.5
3.0
FREQUENCY
HOURS
MARCH OTHER LINE STOP 2016
HOUR FREQUENCY
YTD Loss: $ 3,400
Downtime: 11 Hours

5. Measure
Line D
Line G

6. Measure-Stocking Palletizer Flowchart

7. Analyze-Cause and Effect Diagram
• Irregular Size Pallets
• Protruding Nails
• Chains and Sprockets and
Gears not Covered
• Old Equipment
• No TPM
• No Pallet Inspection Process
• No Specific Directions to
Vendor
• Forklift Operator Not
Trained Properly

8. Analyze
72
60
44
24
21
8
6
0
10
20
30
40
50
60
70
80
Minutes
Reason
Palletizer Down Reasons
PHOTO EYE JAM PALLETS WOULD NOT EJECT LINE DOWN ROLLERS WRAPPER CASES FELL ACTUAL PALLET CAUSING ISSUE

9. Improve
• Remind Pallet Supplier Regarding Our Grade A Pallet Requirement
• Possible Chargebacks If Not Compliant
• Properly Trained Forklift Operator
• He Has To Inspect Pallets Before Stocking
• He Knows What Is Conforming and Nonconforming

10. Improve-Stocking Palletizer Flow Chart

11. Improve

12. Improve
0
10
20
30
40
50
60
1 2 3 4 5 6 7 8 9 10 11 12
Minutes
Run Chart
MINUTES AVG

13. Control

14. Control
March April