2. The ACE Office, Sikorsky Aircraft 2
CH-148 Position 3 Kaizen
Problem Statement
CH-148 Position 3 does not currently meet the 6S Silver standard, a
score of 3.6 or greater. The area is lacking visual aids, proper
staging areas for incoming parts, and visual communication of
aircraft build status.
3. The ACE Office, Sikorsky Aircraft 3
CH-148 Position 3 Kaizen
Team
– Sponsor: Rob Von Stralendorff
– Leader: George Bowman
– Facilitator: Caitlin Murphy
Team Members:
George Bowman – CH-148 Supervisor (1st Shift)
Kelly Nubelo
Dave Little
Jerome Anglin
Andrew Miller – CH-148 Supervisor (2nd Shift)
J.P. Tabbert
Aaron Savela
Debra Carrier – ACE Pilot
David Teixeira – DFC Facilities
PWR – Graphics Department
Mike Burns - EH&S Manager
Bob Dolberg – T-Tools
Kevin Pengue – Tool Crib
Roger Prickett – Material Logistics
Resources:
4. The ACE Office, Sikorsky Aircraft 4
CH-148 Position 3 Kaizen
Kaizen Objectives
• To create a flexible work space that can transition smoothly from
development battleship build to production position build
• To develop a process so only components currently in work will be
present on the manufacturing floor, resulting in a visual pull system
• To create additional workspace so that subassemblies (fairings, racks,
tail rotor pylon, etc) can be built and introduced easily into production
flow
• To introduce visual aids to promote standardization throughout shop
and in staging areas
• To discover and address any EH&S issues on the CH-148 product line
• To work toward a 6S score at or above the Silver level standard by
creating an ordered and efficient work cell including the shop floor
and supervisor areas
5. The ACE Office, Sikorsky Aircraft 6
CH-148 Position 3 Kaizen
Current State
6. The ACE Office, Sikorsky Aircraft 7
CH-148 Position 3 Kaizen
Rubbish bin
Day can
Electrical box
Mechanical box
Sheet metal box
Work table
Panel board4 Step stairs
Counter top
Parts Rack
Solumina terminal
Desk Cabinet2 Step Stairs
Initial Layout
7. The ACE Office, Sikorsky Aircraft 8
CH-148 Position 3 Kaizen
Team Schedule
Time Wednesday Feb 3rd
Thursday Feb 4th
Friday February 5th
11:30 AM
Kick-Off:
Review objectives with
entire group.
Review feedback from 2nd
shift
Brief update from all team
leaders to group
Review feedback from 2nd
shift
Brief update from all team
leaders to group
1:00 PM 15 min break 15 min break 15 min break
2:00-2:30 PM
Communicate objectives
and present status to 2nd
shift
Communicate status to 2nd
shift
Communicate status to 2nd
shift
4:00 PM 15 min break 15 min break 15 min break
5:15 PM Prepare for daily briefing Prepare for daily briefing Prepare for daily briefing
5:30 PM
Management brief
presented by team leaders
Management brief
presented by team leaders
Management brief
presented by team leaders
8. The ACE Office, Sikorsky Aircraft 9
CH-148 Position 3 Kaizen
Needs Assessment
Work surfaces for subassemblies
3 ring binders and tabs
File folders
Supplies
Floor tape, label maker,
laminating supplies, garbage
bags, tie wraps, 1” double-sided
tape, Velcro
6S Training documents
Chart Pad/Easel/Markers
9. The ACE Office, Sikorsky Aircraft 10
CH-148 Position 3 Kaizen
KAIZEN NEWSPAPER
Issue/Opportunity Responsible Due % completion Comments
Identify and remove unnecessary equipment Team 100%
Identify and mark proper staging areas Team 100%
Double-sided signs for Jack Storage and
Recycling Center Caitlin 90% George to request install
Component Staging (POUS) Team 100%
Eyewash (bottles) for A/C stand George/Debbie 100%
Remove T-tooling not in use Tool Crib 100%
Safety glass cleaner for stand Debbie 100%
Ear Plug Dispenser Debbie 100%
Standard Work Signs for Solumina & labor ACE/Supervisors 75% Julian Cox (Solumina)/ Eric Mathias
Standard Work Signs for daily cleaning and
housekeeping George/Red 75% George/Red to review with Black Hawk Supervisors
Move tool boxes and table to top deck Red 100%
Communication board Rob/Red/Caitlin 100%
Replace safety tape on stand Team 100%
Return A/C 801 and 802 hardware to PC Team 100%
Relocate A/C 803 and 804 hardware to
Positions 1 and 2 Team 100%
Collection system for certs. George/Anthony/Kevin L. 90%
Hang warning signs: "Aircraft on Jacks" and
"Radar in Use" Debbie 100%
chairs for this position Kevin/Team 90% Need Blue supervisor chairs
Need string lights inside A/C Kevin/ACE 100%
Order shelves for storage of stools and box
fans Red/Debbie 100%
Relocate Metcals Team 100%
Engineering table for parts/jobs requiring
attention from Engineering Kevin/ACE/Brandon/Red 75% moved to communication board
American flag (and smaller Canadian) for all
work stations Debbie 100% approved
Total: 100%
10. The ACE Office, Sikorsky Aircraft 11
CH-148 Position 3 Kaizen
Staging
Staging
(tooling,
hardware,
etc)
Electrical Area
Engineering
Table
Fairing Area
Communication
Board
Parts Rack
CH-148 Position 3 Jack Storage
New Layout
11. The ACE Office, Sikorsky Aircraft 12
CH-148 Position 3 Kaizen
Staging
Staging
(tooling,
hardware,
etc)
Mech.
Elec.
Electrical Area
Engineering
Table
Fairing Area
Communication
Board
Parts Rack
CH-148 Position 3 Jack Storage
Mech.
Stairs
Stairs
Elec.
60 trips 3min= 3hrs
60 trips X 76ft=4,636ft
60 trips 10 sec.=12min
60 trips X 12ft=720ft
Mechanical Savings: Time 2:48 hrs/Walking 3,916 ft.
Electrical Savings: Time 3:47/walking 3,576 ft.
Mechanical top
Deck 27 AOS’s
Electrical top Deck 2
Major AOS’s80 trips 3min= 4hrs
80 trips X 56ft=4,536ft
80 trips 10 sec.= 13min
80 trips X 12ft=960ft
New Layout Savings: tool box relocation
12. The ACE Office, Sikorsky Aircraft 13
CH-148 Position 3 Kaizen
CH148 Set-up Reduction Event
Feb.19, 2010
Top Deck Electrical and Mechanical AOS’s installs
Mechanical 27 AOS’s Installs
Before
60 trips 3min= 3hrs
60 trips X 76ft=4,636ft
After
60 trips 10 sec.=12min
60 trips X 12ft=720ft
Mechanical Savings: Time 2:48 hrs/Walking 3,916 ft.
Electrical Installs 2 Major AOS’s and multiple minors
Before
80 trips 3min= 4hrs
80 trips X 56ft=4,536ft
After
80 trips 10 sec.= 13min
80 trips X 12ft=960ft
Electrical Savings: Time 3:47/walking 3,576 ft.
New Layout Savings: tool box relocation
13. The ACE Office, Sikorsky Aircraft 14
CH-148 Position 3 Kaizen
New Layout Savings: Metcal Relocation
14. The ACE Office, Sikorsky Aircraft 15
CH-148 Position 3 Kaizen
Metcal's CH-148
Before
Since moving the curtain on the Ch-148
they now have to walk around to get their Metcal's
Feet Minutes
1. Operator goes to the Metcal area 250 15
2. Operator returns to work area 250 5
Total 500 20
3. Process is repeteted Avg. 20 times x20 x20
Total 10,000 400
After
Metcal bins were moved,
to the Ch-148 side and mounted
on wall in central location
Feet Minutes
1. Operator goes to the Metcal area 20 5
2. Operator returns to work area 20 5
Total 40 10
3. Process is repeteted Avg. 20 times x20 x20
Total 800 200
Total Savings = 9,200 200
New Layout Savings: Metcal Relocation
15. The ACE Office, Sikorsky Aircraft 16
CH-148 Position 3 Kaizen
PERFORMANCE
SCHEDULE
TREND HOURS STATUS BOARD
QCPC
TURNBACK TRENDS TURNBACK TRENDS
6SASSESSMENT FORM
6SAUDIT SCHEDULE
6SAUDIT TREND
6SACTION LIST
6S METRICS
AREA OWNERS
1ST SHIFT
PERSONNEL
2ND SHIFT
Description
for all stations,
all shifts
SEATING
Engineering Issues
(dry erase)
Upcoming
Events/Training
(dry erase)
PART SHORTAGES TOOLING/RAWMA NEEDS
MAJOR MILESTONES
Communication Board Layout
(front)
16. The ACE Office, Sikorsky Aircraft 17
CH-148 Position 3 Kaizen
Communication Board Layout
(back)
24 X 36
Dry Erase
(part shortages
noticed during shift
and significant
notes)
12 X 18
MRB
11 X 17
2nd Shift Plan
11 X 17
1st Shift Plan
11 X 17
2nd Crew Load
11 X 17
1st Crew Load
8.5 X 11
Removed
Parts
Bonding
Book
Serial Number
BookElec. CrabsMech.Crabs
11 X 17
Part Shortages
COPQ
COPQ HISTORY
DR HISTORY
CRAB COUNT HISTORY
MRB HISTORY
TIP OF THE DAY
17. The ACE Office, Sikorsky Aircraft 18
CH-148 Position 3 Kaizen
Out Brief Presentation
