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1A. Opportunity: Elimination of Planning Downtime

A3 Report

Team Member
Names:

Site/Plant: Manaus

Date:22/08/2012

Group/Workcell/Site: STB

Leader: Thiego Silva

Annual Savings (US$):

1B. CLARIFY THE PROBLEM:

Rodrigo Marques

Downtime IM / FA

Root Causes

Problem Identification:
High

Where:

IM/FA
Wk 25 ~ Wk 28

How much:

-100% of planning
Downtime is related
to Lack of available
package in the
process.

What:

When:

2. BREAKDOWN THE PROBLEM:

Mentor: Thiego Silva

5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES:

Key Metric to Impact:

High Downtime:
IM / FA

Nattyer Nunes

Selected Countermeasure

Who

Finish

IC Team

WK 1229

WK 1229

Thiego Silva

WK 1229

WK 1229

Providing area for packaging in shelves

15%

There is no
standardization at
location of packages by
size and model.

Separation and standardization of packages location
according to the type
Visual identification of each location for packages

Rodrigo Marques

Data collection – After improvement

Waste(s) Identified

Target

7. EVALUATE RESULTS:

Transportation:

WK 1229

WK 1229

Nattyer Nunes

Planning Downtime
Eliminated

WK 1229

Before

WK 1229

A fter

Inventory:

Savings

Motion:
Waiting:

MVA – Material Value Added
per unit

US$ 6 / unit

MVA / Hour (MVA x Rate)

X

US$ 1422 / h

- 15% of Average
Downtime IM/FA is
related to Planning.

Overproduction:

Defects

Plannig Downtime

5 Hours / Week

- Average Downtime
is 5 hours per week.

Skills Unused

Total Saving/WK

US$ 7110/ Week

Total Saving/Month

US$ 28440 / Month

Over processing

3. SET A TARGET (The challenge):

8. STANDARDIZE:

Eliminate Planning Downtime from 5 Hours per Week to 0 Hours per Week by July 2012.

4. ANALYZE THE ROOT CAUSE:

Environment
- Lack of organization of the location of packages
- The location of packages is not standardized

Planning
Downtime: Lack
of available
package
- Operator loses time when looking for packages

- Employees not trained about how organize the place of package

Method

Means of Standardization:
Standard Work

-Why planning Downtime?
Due lack of available package in the
process
-Why?
Because the packages were not available
when the process was requested.
-Why?
Because operator loses time looking for
packages
-Why?
Due lack of organization of the packages
-Why?
There is no standardization at location of
packages by size and model.

Visual Aids

Global Document /Procedures

Training

Other

X

Process Audits:
LPA

TPM Checklist

5S Audit

X

Other

Next challenge:
- Eliminate buffer and other wastes that can be solved by Planning Team.
Sharing with others:
- Share this project with production leaders and stock area employees.
Lessons Learned:
Visual Management is an important tool. It makes problems visible.
Form #: F-108 - Revision Date: 02/17/2012

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Lean A3 Report for Planning Downtime Elimination

  • 1. 1A. Opportunity: Elimination of Planning Downtime A3 Report Team Member Names: Site/Plant: Manaus Date:22/08/2012 Group/Workcell/Site: STB Leader: Thiego Silva Annual Savings (US$): 1B. CLARIFY THE PROBLEM: Rodrigo Marques Downtime IM / FA Root Causes Problem Identification: High Where: IM/FA Wk 25 ~ Wk 28 How much: -100% of planning Downtime is related to Lack of available package in the process. What: When: 2. BREAKDOWN THE PROBLEM: Mentor: Thiego Silva 5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES: Key Metric to Impact: High Downtime: IM / FA Nattyer Nunes Selected Countermeasure Who Finish IC Team WK 1229 WK 1229 Thiego Silva WK 1229 WK 1229 Providing area for packaging in shelves 15% There is no standardization at location of packages by size and model. Separation and standardization of packages location according to the type Visual identification of each location for packages Rodrigo Marques Data collection – After improvement Waste(s) Identified Target 7. EVALUATE RESULTS: Transportation: WK 1229 WK 1229 Nattyer Nunes Planning Downtime Eliminated WK 1229 Before WK 1229 A fter Inventory: Savings Motion: Waiting: MVA – Material Value Added per unit US$ 6 / unit MVA / Hour (MVA x Rate) X US$ 1422 / h - 15% of Average Downtime IM/FA is related to Planning. Overproduction: Defects Plannig Downtime 5 Hours / Week - Average Downtime is 5 hours per week. Skills Unused Total Saving/WK US$ 7110/ Week Total Saving/Month US$ 28440 / Month Over processing 3. SET A TARGET (The challenge): 8. STANDARDIZE: Eliminate Planning Downtime from 5 Hours per Week to 0 Hours per Week by July 2012. 4. ANALYZE THE ROOT CAUSE: Environment - Lack of organization of the location of packages - The location of packages is not standardized Planning Downtime: Lack of available package - Operator loses time when looking for packages - Employees not trained about how organize the place of package Method Means of Standardization: Standard Work -Why planning Downtime? Due lack of available package in the process -Why? Because the packages were not available when the process was requested. -Why? Because operator loses time looking for packages -Why? Due lack of organization of the packages -Why? There is no standardization at location of packages by size and model. Visual Aids Global Document /Procedures Training Other X Process Audits: LPA TPM Checklist 5S Audit X Other Next challenge: - Eliminate buffer and other wastes that can be solved by Planning Team. Sharing with others: - Share this project with production leaders and stock area employees. Lessons Learned: Visual Management is an important tool. It makes problems visible. Form #: F-108 - Revision Date: 02/17/2012