6. Problems Identified:
– Pressline damage is SEP’s #1 reject.
– Pressline damage and Backrinding make up 27%
of SEP’s rejects.
– There are no formal procedures or work
instructions for the Pressline.
– Press Operators do not receive formal training or
evaluations.
– Press Operators are not aware of the true cost of
rejects or the impact rejects have on the
company.
– Press Operators feel that they don’t have a voice
in troubleshooting and problem-solving problem 6
10. Solutions
•Build a repair table
•Write procedures and work instructions
•Implement formal training on the Pressline
•Engage in open dialogue with the experts that do
the job every day
•Try new mold releases
•New “no-touch” tooling design
•Weekly reject #’s communication
•Initial and periodic evaluations for Press
Operators 10
17. Future State
•Continue to hold regular reviews with
team
•Evaluate true savings realized from
event
•Foster an environment of continuous
improvement
•Apply same Kaizen / Roundtable
meeting process in Steel Prep and
Rubber Prep along with 6S activities
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18. Estimated Cost Savings: Kaizen – Pressline Reject Reduction
IMPACT
Target
Improved Trend Savings Notes
Metric
Waste Cost: $360k projected 2015 waste cost;
$360k x 27% = $97.2k x 50% (projected Pressline
Damage & Backrinding reject reduction) = $48.6k
Waste Cost $48,600
90% reduction of 2 major reject categories
that made up 27% of SEP’s rejects.
Fewer change outs on Pressline due to not
remaking rejects. Time $12,500
27% of rejects reduced by 90% = 20%
fewer setups = 2 setups/day @ 1 hr/setup
x $25/hr x 250 days/yr = $12,500/yr
Reduced shipping costs due to improved on time
delivery. Shipping Cost $5,000
Not shipping pads overnight or next day
due to rejects and frequent late jobs.
Fewer dumpster loads.
Cost $2,400
Reject pad dumpster pickups reduced
from every 6 weeks to every 8 weeks @
$800/pickup = 9x/yr to 6x/yr. 3 x $800 =
$2,400
Total Estimated Savings: $68,500
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