2. 1
Process Mapping
Curtain Machine Production Line
Draft Map
Final Map
CNC
Purchased
Fab
Electronics
Assembly
3. 2
Sample Part
New Machine Setup
Haeger Hardware Insertion Machine
– Develop machine settings for different hardware studs and psi settings for material thickness
– Selection of upper and lower tooling with development of a parts matrix
Stud Top Tool Bottom Tool PSI Setting
S-7436 H-108-0020L H-109-6/m3.5l 1,200
S-6962 H-108-0020L H-103-05L 1,700
S-4330 H-108-0020L H-103-04L 1,700
Part Number Stud Additional Tool PSI
273000 S-4330 11361-1 1,700
Special Tools
4. 3
Time Study
Drive Unit Gearbox and Motor Assembly
Station VA NVA Total Time (sec)
Shaft Assy (St. 1 & 2) 30 0 30
Gearbox Housing (St. 3, 4, &5) 103.5 0 103.5
Shaft Sub Assy (St. 6) 10.67 0 10.67
Gearbox Shaft (St. 7) 7.5 0 7.5
Gearbox Plate (St. 8) 8.57 0 8.57
Gearbox Assy. (St. 9) 81.333 3.5 84.833
Motor Assy. (St. 10) 155.2 2 157.2
Packaging (St. 11) 147.83 20 167.83
570.103
30
103.5
10.67 7.5 8.57
81.333
155.2
147.83
0
0
0 0 0
3.5
2 20
0
20
40
60
80
100
120
140
160
180
Time(sec)
Station
VA vs. NVA
Nonvalue Added
Value AddedDrive Unit with
Gearbox
5. 4
Standard Work
Taking Time Study Information
– Calculate TAKT time
– Calculate ideal number of operators
– Develop current state standardized work
– Align process steps to develop new layout
– Present layout changes, crew planning and standard work changes
Current Process Proposed Process
6. 5
Work Instruction
Develop Work Instruction for Flex Auger Production
– Training tool for new associates
– Standardized practice to reduce
– Operator variation
– Safety checkpoints
– Quality checkpoint
Step
No.
Aux.
No.
Operational Step
Picture
No.
Code Tools
1
Once rack of wire is all used up as shown,
replace with new rack of wire by first
removing the empty returnable wire rack
from the horizontal decoiler using a forklift.
1 & 2 Forklift
2
Move returnable rack from the horizontal
decoiler and set aside and out of the way
on the ground. 3 & 4 Forklift truck
3
Grab returnable rack again with forklift,
sticking the prongs underneath the wire
retaining frame. Use ratchet to loosen the
4 screws that hold the retaining frame to
the rack as shown in picture 6.
5 & 6 Forklift, ratchet
4
Pull wire retaining frame off the top of the
rack and set on top of new coil rack as
shown. Use ratchet, as shown in picture 6,
to tighten the 4 screws of the frame to the
rack.
7 & 8
Manual,
ratchet
5
Lift rack of wire using forklift and move
towards the horizontal decoiler.
9 Forklift truck
PhotosFeature
Data Retention Required
Indicate By an 'R' Inside
The Appropriate Symbol
Code Key
100% Inspection
1st / Every 25th / End
Inspection
CustomInspection
Safety
MF.30XXXX-1
Work Instruction
This instruction applies to any GSI associate forming spring wire.
Issue DateAuthor
Small Spring Wire ProcessTitle
Purpose
To provide a step by step instruction on how to form spring wire
from start to finish.
Scope
Revision Date
Total pages
Horizontal decoiler
Returnable rack
Wire retaining frame
Wire retaining frame
Rack of wire
Part #/ Process
QA Russ Meyer
Production
Nicki Ripperda
Reference Documents
1 2 3
4 5 6
7 8 9
7. 6
Spaghetti Diagram
Spaghetti Diagram
– Operator observation to determine common patterns of travel
– Spaghetti Diagram on small parts packaging in finished goods
8. 7
Control Plan
Develop Control Plan for production of galvanized fan process
– Use previously made work instructions
– Describe the actions required to assure that all phases of the process are in a state of control
– Important tool for APQP (Advanced Product Quality Planning)
9. 8
Capability Study
Hog Feeder Trough Capability Study
– Measured five different critical measurements on 30 troughs of new hog feeder design
– Entered data into Minitab program
– From Minitab calculations, determined current process is not capable of repeatedly producing
parts within product specification
– Determined how much the tolerance on the blueprint would need to change in order for the
process to become capable
Current State Proposed State with tolerance change
Hog Feeder
Trough
