This document summarizes a kaizen event aimed at reducing wiring rework hours in a metal clad production line. The event agenda included creating a process flow diagram and failure mode and effects analysis to identify causes of rework. An action plan was developed to reduce rework costs and defects in the short and long term. Metrics such as rework cost, hours and defects were identified to measure progress. The timeline laid out the define, measure, analyze, improve and control phases. Engineering and production teams participated in the event to improve wiring processes.

1. April 18th
, 2016
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Kaizen Event: Reduction of Wiring
Rework Hours in MetalCLAD
Update To Ted Klee

2. 2
SPS-0159EN V01 Kaizen Report Template
AGENDA
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1. Project charter
2. RACI chart
3. Process Flow Diagram : Engineering / Manufacturing
4. Process Failure Mode Effect Analysis (PFMEA)
• Failure Mode Cause
• Severity / Occurrence / Detection (S-O-D)
5. Action Plan (short term and long term)
6. Effect Benefit Diagram
7. Kaizen Follow-up Calls : Sustainability

3. 3
SPS-0159EN V01 Kaizen Report Template
Confidential Property of Schneider Electric
 60% of the rework cost in Metal
Clad Line is due to OCNs for last 3
Months in Smyrna Plant
 Rework cost is calculated with
the hours spent on rework that is
collected on Auto time by the
operators through out the
manufacturing Line.
Goals/objectivesGoals/objectives
Reduce defect in wiring process from 4400
To 3500 (YTD 2015 data from quality).
Reduce Rework Cost wiring by15%.
 Corrective actions identification and quick
actions implementation from PFMEA
Improve Defect Collection process to
include defects through out manufacturing
process
Sustain the new process with proper
documentation, PCP record, NQC calculation
correction (to include Rework Cost)
ScopeScope
 Wiring: From OCN changes to
Metal Clad wiring process and
excludes mechanical assembly of
Metal Clad and all other Production
Lines.
TeamTeam
Leader : Muhammad Ali
Sponsor : Lonnie T/David
M
Coach : Carrie House
Process Owner :
Muhammad Ali/Production
Supervisor
Leadership Core Team Extended Team
QE : Chelsea Scialabba (100%)
ME : Ryan Teter (50%)
Application Eng : Richa Gokhale(100%)
Harshada Pendse (100%)
Operator : Ueursu Hall (50%)
Production Supervisor : Amable Osborne
(100%)
Electrical Designer: Haris Shaukat (100%)
Eng Supervisor : Muhammad Ali (100%)
Quality Expert : Serge
Lardinois
ETO Expert : Herve Raoult
SPS Specialist : Leticia Rivera
CI Lead : Rohini B Prabhakar
Testing Sup: Shana Summers
(100%)
Business ImpactBusiness Impact
Reduce Rework cost due to wiring
by15%
Reduce NQC (after correction)
Measures / KPI’sMeasures / KPI’s
Rework Cost
Rework Hours
MQD
Risk AssessmentRisk Assessment
 Lead-time Impacted by
Engineering Process & Tools
TimelineTimeline
Define : 02/2516 – 03/02/16
Measure : 02/25/16 – 03/02/16
Analyze : 03/03/16 – 03 /14/16
Improve : 03/15/16-03/17/16
Control : 03/18/16- 04/25/16
CausesCauses
 With Brainstorming exercise , we came up
with rework happening due Customer
Change, Engineering Errors, Delayed
customer feedback, not following correct
revision of prints, Engineering documents not
released in time to shop floor.
Project Name : Reduce Rework
Hours in Metal Clad Production
Line
Project Name : Reduce Rework
Hours in Metal Clad Production
Line
Project Leader : Muhammad
Ali
Project Leader : Muhammad
Ali Project Sponsor : Lonnie Tolbert/David MabiusProject Sponsor : Lonnie Tolbert/David Mabius

4. 4
SPS-0159EN V01 Kaizen Report Template
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Preparation:
Define objective
Measure current
state
Event:
Change the
process
Sustain:
Improve and
control the
changes
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Preparation Phase – RACI chart
RESPONSIBLE ACCOUNTABLE CONSULTED INFORMED
ENGINEERING
(OCN/PFMEA/PCP)
Muhammad Ali Richa G
Harshada P
Muhammad Ali
Haris S
Lean Master Team David M
Engineering Team
PRODUCTION
(Wiring PFMEA)
Amable O Chelsea S
Ryan T
Shana S
Lean Master Team
Production
Operators
Chris Lee
QUALITY
(NQC/ PCP)
Shana Summers
Chelsea
Chelsea S
Brandon
Quality Team
Lean Master Team
Sheri Lau &
Management Staff

5. 5
SPS-0159EN V01 Kaizen Report Template
Event - Team Members (March 15-17,2016)
Preparation:
Define objective
Measure current
state
Event:
Change the
process
Sustain:
Improve and
control the
changes
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6. 6
SPS-0159EN V01 Kaizen Report Template
Event – ENGG PFMEA creation
Preparation:
Define objective
Measure current
state
Event:
Change the
process
Sustain:
Improve and
control the
changes
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1. Team was instructed to take 1.5 hrs E-Learning on Basic FMEA
2. 2 Hr FMEA was provided with examples in the beginning of the Event
3. Step by Step Analysis for Failure Modes, Prevention Controls, Detection
Points and Root Causes driven by Smyrna Team
Click here for detailed PFMEA spreadsheet

7. 6
SPS-0159EN V01 Kaizen Report Template
Event – ENGG PFMEA creation
Preparation:
Define objective
Measure current
state
Event:
Change the
process
Sustain:
Improve and
control the
changes
>
>
1. Team was instructed to take 1.5 hrs E-Learning on Basic FMEA
2. 2 Hr FMEA was provided with examples in the beginning of the Event
3. Step by Step Analysis for Failure Modes, Prevention Controls, Detection
Points and Root Causes driven by Smyrna Team
Click here for detailed PFMEA spreadsheet