7. ACT
• Areas of extension in the dept.
– Taylor Windfield
– North Weldex
– South Weldex
– Pack off
– Meritech’s
– Bondcell
8. Results
• 15 high risks reduced to 0 = 100% reduction in
HIGH risks.
• 3 quick and 5 standard kaizens written.
• 73 Total risk reduction points across the dept.
• Step 3 completed and moved into step 4.
13. 0
200
400
600
800
1000
1200
1400
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1st
2nd
Range: 1100±150
(6/1-6/20)
OUTLIERS
For the first three weeks of June: 1st shift
averaged 1100 and 2nd shift averaged
1092!
14. With the proposed
packing method, the
operator does not have
to make this flip before
the cover is placed on
the piston.
This method takes 3 seconds to
complete and is less of an ergonomic
strain on the operator.
15.
16. • This project idea was read across to Dept. 9821 on three different lines to
eliminate 3 level 2 Muri’s and account for $14,518.00 savings.
18. Gemba
“Go to the operation”
Gembutsu
“Talk to the operators and floor workers.”
Genjitsu
“Collect and analyze data
to apply
countermeasures.”
“Genri”
Determine root cause.
“Gensoku”
Standardize and read across to other areas.
19. 5 Why’s?
• Problem: Based on CD 11 op 50 pivot bracket welder has been charged
with $254,000 of micro-stoppages.
– Why?: The pivot welder has numerous faults per shift.
– Why?: The inner jacket bore faults out many times a day which causes the pivot welder
to fault out.
– Why?: Gantry #1 accounts for over 50% of all inner jacket bore faults.
– Why?: The sensors were dirty, the grippers were low on air pressure and the in feed
conveyor was out of synchronization with the inner bore.
– Why?: Lack of specific AM, programing software was not adjusted when inner bore was
worked on resulting in faulty communication between the two machines.
20. • Currently this project is in step 5 of the 7 steps of micro stop elimination. We
are checking our effective countermeasures thus far.
• A team is in place to identify the root causes for the remaining 50% of micro
stops at this machine.
• This project was chosen as one of 9 to be shown in the WCM audit and is
projected to save over $200,000.
Where we are headed
21. Current Projects
• 9826 Micro stop project with Straddle
Mill. (Check phase)
• 9826 project with AM cleaning. (Do
phase)
• 9826 JSRA reduction’s plan for step 4.
• 9853 Silo project. (Do phase)
22. Summary
Closed project savings
• 73 JSRA points reduced
• 5 level 2 Muri risks eliminated.
• $38,111.75
• 9854 up a safety step
Open projects savings
• $232,867
• 39 JSRA points
• 3 level 1 Muri Risks
• 9826 up a safety step
Valuable real world
training and
experience!!
