This document summarizes an analysis of cell F119. It identifies four part numbers processed in the cell with travel times. It also lists some manufacturing processes occurring in the cell like lathe and mill. The document recommends reorganizing the cell layout to reduce travel times and balance work content. A rapid assessment was conducted on the cell over three days reviewing processes, defining value-added vs. non-value added work, and developing a future state map and new layout with an U-shape to reduce waste. An action plan was created to implement the changes.

2. F119 Cell Analysis

3. F119 Cell Analysis524P229-01 (408’)524P240-01 (333’)524P241-01 (222’)524P235-01 (525’)

4. F119 Cell Analysis524P229-01 (408’)524P240-01 (333’)524P241-01 (222’)524P235-01 (525’)

5. F119 Cell Analysis524P229-01 (408’)524P240-01 (333’)524P241-01 (222’)524P235-01 (525’)

6. F119 Cell Analysis524P229-01 (408’)524P240-01 (333’)524P241-01 (222’)524P235-01 (525’)Lathe

7. F119 Cell Analysis524P229-01 (408’)524P240-01 (333’)Mill524P241-01 (222’)524P235-01 (525’)Lathe

8. F119 Cell Recommendations Move Processes in Line

9. Manual/Tumble Deburr

10. Wash

11. Inspection

12. Packing

13. Re – Layout Cell to significantly reduce Travel Times

14. Analyze and Balance Work ContentRapid Assessment

15. Rapid Assessment

16. Rapid Assessment

18. Sept 8 – 10, 2009Trust Technologies, Inc – Mentor, OhioWaste Reduction WorkshopF119 Cell Pt # 524P235-01

19. The TEAM14

20. Agenda – Hoshin WorkshopDay One 8am to 4pm

21. 20 Principles & 7 concepts of Lean –John Petak

22. 8 Forms of “TIM WOOD “ Waste – John Petak

23. 6 Rules of Quality – drive Quality First concept – John Petak

24. Defined 17 process steps VA 41% NVA 59% - Team

25. Defining the Current State VSM – Team (High Level Map) -Team

26. Calculate Takt Time for 4 part references TT = 114 minutes or 6857 sec - TeamAgenda Hoshin WorkshopDay Two