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Lecture 7b

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Lecture 7b

  1. 1. KATA © 2016 The Leadership Network® © 2016 Jidoka® 01 Storyboard and Kata forms to supplement the Coaching Scripts 1. Learner’s Story Board, slides are 36” x 48“, Landscape 2. All other forms are 8.5”x11”, OR 11” X17” Landscape Supplement Lecture 7b Rev. 09.21.2016
  2. 2. KATA © 2016 The Leadership Network® © 2016 Jidoka® 02 Focus Process: Challenge: Target Condition Achieve by: 06.10.2016 Current Condition It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No Overtime Process Metrics Process Metrics Outcome Metrics Outcome Metrics F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: ACME Machining Cell First Pass Yield > 98% Mill Reliability > 90% PPLH > 50 Scrap < 3.5% Overtime = 0% Scene 1 Script
  3. 3. KATA © 2016 The Leadership Network® © 2016 Jidoka® 03 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: First Pass Yield > 95% Mill Reliability > 85% PPLH > 37.5 Scrap < 5% Overtime < 10% Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 2 Script
  4. 4. KATA © 2016 The Leadership Network® © 2016 Jidoka® 04 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: First Pass Yield > 95% Mill Reliability > 85% PPLH > 37.5 Scrap < 5% Overtime < 10% Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 3 Script Obstacle 1 2 3 4 5 Workload on operators Scrap OBSTACLES PARKING LOT How will you measure that? Less number of Hobs Less number of Turning Mills
  5. 5. KATA © 2016 The Leadership Network® © 2016 Jidoka® 05 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #0 -Slide 13 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: First Pass Yield > 95% Mill Reliability > 85% PPLH > 37.5 Scrap < 5% Overtime < 10% Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 4 Script Fi. 5
  6. 6. KATA © 2016 The Leadership Network® © 2016 Jidoka® 06 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #1 -Slide 14 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 5 Script
  7. 7. KATA © 2016 The Leadership Network® © 2016 Jidoka® 07 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #2 -Slide 15 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: PDCA #3 -Slide 16 Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 6 Script
  8. 8. KATA © 2016 The Leadership Network® © 2016 Jidoka® 08 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #2 -Slide 15 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: PDCA #4 -Slide 17 Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 7 Script
  9. 9. KATA © 2016 The Leadership Network® © 2016 Jidoka® 09 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #5 -Slide 19 PDCA #4 - Slide 18 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 8 Script
  10. 10. KATA © 2016 The Leadership Network® © 2016 Jidoka® 10 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #6 -Slide 20 PDCA #4 – Slide 18 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 9 Script
  11. 11. KATA © 2016 The Leadership Network® © 2016 Jidoka® 11 Target Condition Achieve by: 06.10.2016 Current Condition Process Metrics Process Metrics Outcome Metrics Outcome Metrics PDCA #6 -Slide 21 PDCA #7 – Slide 22 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability: Focus Process: Challenge:It would be Colossal, if by 1.1.2017, the ACME machining cell occupied 50% less floor space, operating 2 shifts with 50% of the machinery, so we can achieve: 50 PPLH, <3.5% Scrap, with No OvertimeACME Machining Cell Scene 10 Script
  12. 12. KATA © 2016 The Leadership Network® © 2016 Jidoka® 12 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 05-26-16 Process: Hob Machining of gear Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time Process Metric: Number of Hob machines operating Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-26-16 Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order. And I want to get an estimate of when they will be ready to test the two Hob machines that are down. I expect to learn that we have been waiting for parts and to learn when machines will be ready to test TIME: 11:00 AM “Go See” X “Exploratory” “Hypothesis” DATE: TIME: “Go See” “Exploratory” “Hypothesis”
  13. 13. KATA © 2016 The Leadership Network® © 2016 Jidoka® 13 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 05-26-16 Process: Hob Machining of gear Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time Process Metric: Number of Hob machines operating Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-26-16 Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order and estimate of when they will be ready to test the two Hob machines that are down. I expect to learn that we have been waiting for parts and to learn when machines will be ready to test TIME: 11:00 AM “Go See” X “Exploratory” “Hypothesis” DATE: 5-27-16 I will collect all hourly computer reports from each Hob on first and second shift and compare them looking for any changes in quality standards. I will track how many cycles of the machines to see if they fail before the end of a 50 piece sample run on this shift. I will learn how many Hobs can run quality pieces consistently and if we need to shorten number of cycles between shifts. TIME: 10:30 AM “Go See” x “Exploratory” “Hypothesis”
  14. 14. KATA © 2016 The Leadership Network® © 2016 Jidoka® 14 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 05-26-16 Process: Hob Machining of gear Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time Process Metric: Number of Hob machines operating Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-26-16 Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order and estimate of when they will be ready to test the two Hob machines that are down. I expect to learn that we have been waiting for parts and to learn when machines will be ready to test TIME: 11:00 AM “Go See” X “Exploratory” “Hypothesis” DATE: 5-27-16 I will collect all hourly Gleason reports from each Hob on first and second shift and compare them looking for any changes in quality standards. I will track how many cycles of the machines to see if they fail before the end of a 50 piece sample run on this shift. I will learn how many Hobs can run quality pieces consistently and if we need to shorten number of cycles between shifts. 10 out of 18 machines we started with on 5-27- 16 all are still running quality pieces after an average of fifty cycles, and 50 quality parts have been produced. I wanted to put all ten Hobs through a complete 8 hour shift, however, we are waiting on two out of the ten Hobs to be fixed for production. That we have 10 out of 18 machines that are consistently running quality pieces If I had the opportunity to conduct this PDCA again, I wouldn't do anything differently. I learned we have enough Hobs running to meet goal of 2200 pieces per shift. TIME: 10:30 AM “Go See” x “Exploratory” “Hypothesis”
  15. 15. KATA © 2016 The Leadership Network® © 2016 Jidoka® 15 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 5-31-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Save time checking pieces Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-31-16 Work with operators to find the best place for second check station at end of line To help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts I expect to find a place to set up at second check station. It will help reduce time walking back and forth to check parts.TIME: 11:00 AM “Go See” “Exploratory” X “Hypothesis” DATE: TIME: “Go See” “Exploratory” “Hypothesis”
  16. 16. KATA © 2016 The Leadership Network® © 2016 Jidoka® 16 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 5-31-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Save time checking pieces Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-31-16 Work with operators to find the best place for second check station at end of line To help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts I expect to find a place to set up at second check station. It will help reduce time walking back and forth to check parts. It took an average of ten seconds longer to check parts at the table in between Hobs than the table in middle of line. We have enough gages on line for both sides of line. Run-out is an hourly check that is charted. I learned that a table at middle of line would be better and that we have enough gages on the line. If I had to do this over again, I would have tried to find a table for the center of line In my next PDCA, I will set a table up and start working on finding the most efficient place for checking part quality. TIME: 11:00 AM “Go See” X “Exploratory” “Hypothesis” DATE: 6-01-16 Set up a quality check station at the head of the line. Have each operator run five machines and collect data. We will record the number of pieces produced and how many hob adjustments, are needed for part quality. We will test this with 1 operator on second shift and 2 operators on first shift for two hours I expect to learn the average parts that an operator can run on five machines and the amount of time spent making adjustmentsTIME: 11:00 AM “Go See” “Exploratory” X “Hypothesis”
  17. 17. KATA © 2016 The Leadership Network® © 2016 Jidoka® 17 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 5-31-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Save time checking pieces Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 5-31-16 Work with operators to find the best place for second check station at end of line To help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts I expect to find a place to set up at second check station. It will help reduce time walking back and forth to check parts. It took an average of ten seconds longer to check parts at the table in between Hobs than the table in middle of line. We have enough gages on line for both sides of line. Run-out is an hourly check that is charted. I learned that a table at middle of line would be better and that we have enough gages on the line. If I had to do this over again, I would have tried to find a table for the center of line In my next PDCA, I will set a table up and start working on finding the most efficient place for checking part quality. TIME: 11:00 AM “Go See” X “Exploratory” “Hypothesis” DATE: 6-01-16 Set up a quality check station at the head of the line. Have each operator run five machines and collect data. We will record the number of pieces produced and how many hob adjustments, are needed for part quality. We will test this with 1 operator on second shift and 2 operators on first shift for two hours I expect to learn the avg parts that an operator can run on 5 machines and the amount of time spent making adjustments. I am unsure if we can produce 500 quality parts over a 2 hour period, which is what is necessary to cover the customer demand for production I expect Charles on 1st shift will produce more parts than James on 2nd shift due to training Jennifer, new operator The operator averaged 413 over two hours. Charles produced 350 James produced 583 Jennifer produced 308 (in training). So, James on 2nd shift actually produced more that Charles on first shift, even though he was training Jennifer as well as running his own production requirements. This was an unexpected surprise. It was reported that it is possible to run over 500 parts in two hours. I will talk with James to see if he ran any differently than Charles or Jennifer. When all machines are available to run I don’t believe it will be a problem to reach desired number of 500 quality parts produced over a two hour period. We should be able to revise the standard work to match James’ best practice. TIME: 11:00 AM “Go See” “Exploratory” X “Hypothesis”
  18. 18. KATA © 2016 The Leadership Network® © 2016 Jidoka® 18 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 6-02-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Shared labor Hob/shape Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) DATE: 6-02-16 Have the first operator work at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift. The first operator will then move to Shaper cell for the remainder of shift I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should increase output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH) TIME: 2:00 “Go See” “Exploratory” X “Hypothesis” DATE: TIME: “Go See” “Exploratory” “Hypothesis”
  19. 19. KATA © 2016 The Leadership Network® © 2016 Jidoka® 19 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 6-02-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Shared labor Hob/shape Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 6-02-16 Have the first operator work at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift. The first operator will then move to Shaper cell for the remainder of shift I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should increase output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH) Operator 1 ran 380 parts at the Hobs for the first 2.5 hours running six Hob machines He ran 394 at the Shaper machine in 5 hours running 4 shaper machines I learned that reaching 500 at Hobs in 2.5 hours is possible. The operator is a new employee (less than 90 days) and should get faster with more time, training and experience. If six Shaper machines are running getting 600 in 5.5 hours, then it should be easy for the Shaper machines to average 20 parts per hour per machine TIME: 2:00 “Go See” “Exploratory” X “Hypothesis” DATE: 6-03-16 I plan to have 1 operator on first shift run a layout of 6 Hobs inline with check station at both ends of the line. I will compare this to a layout of 6 Hobs in a U- shape cell to see if this is an advantage to running with the U- shaped cell layout and the two check stations. I expect there will not be a advantage running U-shaped for six hours a day after time spent adjusting machines and quality checking the first pieces. TIME: 11:00 “Go See” “Exploratory” X “Hypothesis”
  20. 20. KATA © 2016 The Leadership Network® © 2016 Jidoka® 20 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 6-02-16 Process: Hob Machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Shared labor Hob/shape Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 6-02-16 Have the first operator work at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift. The first operator will then move to Shaper cell for the remainder of shift I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should boost output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH) Operator 1 ran 380 parts at the Hobs for the first 2.5 hours running six Hob machines He ran 394 at the Shaper machine in 5 hours running 4 shaper machines I learned that reaching 500 at Hobs in 2.5 hours is possible. The operator is a new employee (less than 90 days) and should get faster with more time, training and experience. If six Shaper machines are running getting 600 in 5.5 hours, then it should be easy for the Shaper machines to average 20 parts per hour per machine TIME: 2:00 “Go See” “Exploratory” X “Hypothesis” DATE: 6-03-16 I plan to have 1 operator on first shift run a layout of 6 Hobs inline with check station at both ends of the line. I will compare this to a layout of 6 Hobs in a U- shape cell to see if this is an advantage to running with the U- shaped cell layout and the two check stations. I expect there will not be an advantage running U-shaped for six hours a day after time spent adjusting machines and quality checking the first pieces. The operator ran 1344 parts with the Hob machine running inline. The operator produced 1837 running in a U- shaped cell. Operator said that he must cold start every machine now that there isn’t a third shift. Running warm up cycles and one piece load to check size and make adjustment. He ran 84 for his first hour. He also had machine down waiting for Hob to be sharpened He ran machines in another line. I learned that the U- shaped cell layout produced over 500 additional parts. However, we are losing production because of cold start up with no parts in que as we had running 3 shifts. I learned that running the machines in straight line didn’t produce as many parts as the U-shaped cell on first shift. TIME: 11:00 “Go See” “Exploratory” X “Hypothesis”
  21. 21. KATA © 2016 The Leadership Network® © 2016 Jidoka® 21 KATA PDCA CYCLES RECORD(each row = one experiment) Date: 6-6-16 Process: Hob machining of gears Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts Process Metric: Straight line verses U-shaped cell Learner: Terry Coach: John Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened? (observe) What did you learn? (what you expected? / what happened?) DATE: 6-6-16 I plan to have an operator on second shift run a straight inline layout of the 6 Hobs with check station at both ends of Hob line. We will leave al parts in que from first shift. I want to see how many parts are gained in comparison to the cold starting without parts in que. There should not be the down time waiting on the first piece at packaging I expect that the inline layout without the delay from the cold startup will produce the same production output numbers. I expect this will be closer to the same production as running the U-shaped cell. TIME: 11:00 “Go See” X “Exploratory” “Hypothesis” DATE: TIME: “Go See” “Exploratory” “Hypothesis”
  22. 22. KATA © 2016 The Leadership Network® © 2016 Jidoka® 22 1 2 3 4 We have 1,000 pcs in inventory at the start of the line; all other machines produce in flow We check quality according to a sampling plaan of 6 parts every 15 minutes. We 100% final audit per customer contract requirements at pack. BLOCK DIAGRAM OBSERVATIONS 1,000 pcs Due to diminishing production volume we have exess capacity in our Hob Machines and Turning Mills. CONDITIONCURRENT HOB1 HOB2 HOB 3 HOB4 HOB5 HOB6 HOB7 HOB8 HOB9 HOB10 HOB11 HOB12 HOB13 HOB14 HOB15 HOB16 HOB17 HOB18 Shaper 1 Shaper 2 Shaper 3 Shaper 4 Shaper 5 Shaper 6 CNC Machine 1 CNC Machine 2 Turning Mill 1 Turning Mill 2 Turning Mill 3 Turning Mill 4 Final Audit and PAck I QA Turning Mill 5 Turning Mill 7 Turning Mill 6 Turning Mill 8
  23. 23. KATA © 2016 The Leadership Network® © 2016 Jidoka® 23 1 2 3 4 1,000 pcs BLOCK DIAGRAM OBSERVATIONS CONDITIONTARGET HOB1 HOB2 HOB3 HOB4 HOB5 HOB6 HOB7 HOB8 HOB9 HOB10 Shaper 1 Shaper 2 Shaper 3 Shaper 4 Shaper 5 Shaper 6 CNC Machine 1 CNC Machine 2 Turning Mill 1 Turning Mill 2 Turning Mill 3 Turning Mill 4 Final Audit and PAck I QA
  24. 24. KATA © 2016 The Leadership Network® © 2016 Jidoka® 24 F/A - Pack Mill 8 Mill 7 Mill 6 Mill 5 Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 18 Hob 17 Hob 16 Hob 15 Hob 14 Hob 13 Hob 12 Hob 11 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 OTHER PROCESS METRICS: Mill Reliability is 80% Overtime is due to machine reliability at Turning Mills 1,7, & 8 NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: We have excess capacity and high variation in machine cycle with our Hob Machines. Hob 18 cycle time exceeds Takt Time We have excess capacity and high variation in machine cycle with our Turning Mill Machines. PPLH = 27.5 Scrap = 6.7% OverTime = 8% First Pass Yield = 93% Exit Cycle Var(Pack) = 10 s +/- 12% Hob 18 Lowest Repeatable Hi Var = +195% Lo Var = - 24%= 14 seconds Takt Time = 12.3 seconds Planned Cycle Time= 10.5 Seconds Number of Shifts = 3 Number of Operators = 10 CURRENT CONDITION SUMMARY SHEET Outcome Metrics (See Charts) Process Stability:
  25. 25. KATA © 2016 The Leadership Network® © 2016 Jidoka® 25 F/A - Pack Mill 4 Mill 3 Mill 2 Mill 1 CNC 2 CNC 1 Shaper 6 Shaper 5 Shaper 4 Shaper 3 Shaper 2 Shaper 1 Hob 10 Hob 9 Hob 8 Hob 7 Hob 6 Hob 5 Hob 4 Hob 3 Hob 2 Hob 1 Hob 0 Hob 1 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 Outcome Metrics (See Charts) Process Stability: Mill Reliability is 90% TARGET CONDITION SUMMARY SHEET Machine cycle and capacity is balanced awith 10 Hobs None of the Hob cycle times exceed Takt Time Machine cycle and capacity is balanced awith 4 Turning Mills Number of Operators = 10 Number of Shifts = 3 OverTime = 10% Planned Cycle Time= 10.5 Seconds NOTES AND OBSERVATIONS PROCESS CHARACTERISTICS: OTHER PROCESS METRICS: Takt Time = 12.3 seconds Hob Lowest Repeatable = 10 seconds Exit Cycle Var(Pack) = 10 s +/- 10% Hi Var = +15% Lo Var = - 15% First Pass Yield = 96% PPLH = 37.5 Scrap = 5.0%
  26. 26. KATA © 2016 The Leadership Network® © 2016 Jidoka® 26
  27. 27. KATA © 2016 The Leadership Network® © 2016 Jidoka® 27
  28. 28. KATA © 2016 The Leadership Network® © 2016 Jidoka® 28
  29. 29. KATA © 2016 The Leadership Network® © 2016 Jidoka® 29
  30. 30. KATA © 2016 The Leadership Network® © 2016 Jidoka® 30
  31. 31. KATA © 2016 The Leadership Network® © 2016 Jidoka® 31
  32. 32. KATA © 2016 The Leadership Network® © 2016 Jidoka® 32 KATA PDCA CYCLES RECORD(each row = one experiment) Date: Process: Obstacle: Process Metric: Learner: Coach: Date, Time, Type, Step & Metric What do you expect? Coaching Cycle Experiment What happened (observe closely)? What did you learn? (what you expected? / what happened?) DATE: TIME: “Go See” “Exploratory” “Hypothesis” DATE: TIME: “Go See” “Exploratory” “Hypothesis” SPECIFIC DETAILS OF THE STEP SPECIFIC DETAILS OF HOW IT WILL BE MEASURED DOES THIS STEP BUILD FROM THE PREVIOUS PDCA? MAKE A PREDICTION IF INTRODUCING A CHANGE, WHAT IMPACT WILL IT HAVE ON METRICS? FACTS AND DATA HERE ABOUT THE PROCESS? ABOUT SCIENTIFIC PROBLEM SOLVING? IF YOU WERE DOING THIS PDCA AGAIN, WHAT WOULD YOU DO DIFFERENTLY? HOW WILL THIS IMPACT YOUR NEXT PDCA? SPECIFIC DETAILS OF THE STEP SPECIFIC DETAILS OF HOW IT WILL BE MEASURED DOES THIS STEP BUILD FROM THE PREVIOUS PDCA? MAKE A PREDICTION IF INTRODUCING A CHANGE, WHAT IMPACT WILL IT HAVE ON METRICS? FACTS AND DATA HERE ABOUT THE PROCESS? ABOUT SCIENTIFIC PROBLEM SOLVING? IF YOU WERE DOING THIS PDCA AGAIN, WHAT WOULD YOU DO DIFFERENTLY? HOW WILL THIS IMPACT YOUR NEXT PDCA?

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