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Harish Kumar Shahi completed a summer internship at Axalta Coating Systems where he worked on three projects: optimization of extruders, analysis of product wheel sequencing, and development of a planning software tool. He analyzed the constraints and throughput of eight extruders, identifying issues like cooling problems. This led to an average 10% increase in throughput. He also analyzed moving from bucket to product wheel sequencing, finding potential inventory and cost savings. Finally, he developed a software tool to optimize production planning and inventory levels.

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HARISH KUMAR SHAHI MBA,BAUER COLLEGE OF BUSINESS UNIVERSITY OF HOUSTON SUMMER INTERNSHIP PROJECT OPERATIONS May - August 15
Axalta Coating Systems PROJECTS UNDERTAKEN DURING INTERNSHIP Worked on 3 projects during my internship.  Optimization of Extruders.  Complete analysis on Product Wheel  Development of Planning software tool 2 Analysis
Axalta Coating Systems OPTIMIZATION OF EXTRUDERS 3
Axalta Coating Systems OBJECTIVE  Find the constraints in achieving the maximum throughput.  Find the new run condition for the machines.  Analyze the increase in the Throughput (lbs/hr) in this process.  Recommendations to maintain these operation conditions in future. 4
Axalta Coating Systems 5 EXTRUDER 1 Date Product Name Scre w Spee d Final Feeder Speed Initial Speed (If changes were not made) Initial Throughp ut (lbs/hr) Final Thro ughp ut (lbs/h r) Increas e in Throug h Put (lbs/hr) Major Constraint Identified 27- May 72514LGE 475 235 225 2105 2105 0 Cooling belt problem: Not enough Cooling 28- May 72501 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 29- May 72500 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 30- May 7200 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 1-Jun FBE PIPE POWDER 475 250 225 2160 2400 240 Cooling belt problem: Water sprinklers not working 2-Jun RISER GREY III 400 300 200 1800 2300 500 Cooling belt problem: Water sprinklers not working 3-Jun GREY NAP-ROCK 475 250 180 1700 2360 660 4-Jun GREY NAP-ROCK 475 200 180 1700 1890 190 Cooling belt problem: Water sprinklers not working 5-Jun RISER GREY III 400 200 180 1860 2060 200 31-Jul RISER GRAY II 475 250 225 1940 2160 220 AVERAGE 1896 2169 273 % INCREASE IN THROUGH PUT 14% Procedure Followed 1.Look up at the daily running conditions( Feeder Speed, Screw speed). 2. What is the history of running the same product. 3.Try to increase the feeder speed and accordingly make changes in other parameters (Cooling Belt speed) 4. Identify the constraints 5. Analyze the changes the throughput.
Axalta Coating Systems Initial Average Throughput(lb/hr) Final Average Throughput(lb/hr) % Increase Extruder 1 1896 2169 14% Extruder 2 1428 1651 16% Extruder 3 1685 1807 7% Extruder 4 400 400 0% Extruder 5 448 516 15% Extruder 6 495 536 8% Extruder 7 1462 1603 10% Extruder 8 1461 1609 10% Average 10% 6 COMPARISON OF INITIAL AND FINAL THROUGHPUTS 0 500 1000 1500 2000 2500 Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Comparison of Initial and Final Throughputs Initial Throughput Final Throughput
Axalta Coating Systems 7 CONSTRAINT ANALYSIS Different Constraint Identified Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Cooling belt problem / Material stacks up at the break rolls 43% 0% 0% 0% 0% 0% 21% 20% Material backs up in feeder Hopper 10% 0% 71% 0% 83% 63% 32% 33% Feeder Load variations 10% 0% 0% 0% 0% 0% 0% 0% Potential to increase the Feeder Speed. 0% 40% 7% 0% 0% 13% 32% 27% Re Extrusion Material Spilling 0% 0% 0% 0% 17% 25% 0% 0% ACM/Tubs not available 38% 60% 21% 0% 0% 0% 16% 20% 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Cooling belt problem / Material stacks up at the break rolls Material backs up in feeder Hopper Feeder Load variations Potential to increase the Feeder Speed. Re Extrusion Material Spilling ACM/Tubs not available
Axalta Coating Systems 8 CONSTRAINTS PROPORTIONS Cooling belt problem / Material stacks up at the break rolls 12% Material backs up in feeder Hopper 42% Feeder Load variations 1% Potential to increase the Feeder Speed. 17% Re Extrusion Material Spilling 6% ACM/Tubs not available 22%
Axalta Coating Systems Recommendations  Find the solution for the problem of backing up of material in the hopper. Equipment modification such as Design changes in screws.  Better Cooling system. Maintenance of sprinklers Design modification  Better Communication with the operators. Need to work with engineer to develop new run conditions for the machines as per the data collected for last 3 months.  We should work on the ACMs to increase the Throughput by analyzing various run conditions. 9
Axalta Coating Systems COMPLETE ANALYSIS OF PRODUCT WHEEL 10
Axalta Coating Systems Background Presently Bucket sequencing is followed at the site. The products are sequenced on the weekly bucket basis as per the demand . In this process cleaning has to be done more often. This increases the productivity cost. Wheel sequencing is sequencing of products as per consistent cycle. It helps in reducing the cleaning time, inventory cost and in turn total production cost. 11
Axalta Coating Systems To understand if Wheel sequencing will be Beneficial? What is Product wheel? Production sequence used by a manufacturing operation when multiple products are made on a single line/piece of equipment  Consistent sequence  Repetitive time cycle 12
Axalta Coating Systems Benefits  Decreases controllable fixed costs  Provides framework for establishing customer order lead times  Provides understanding of relationship between transition cost and inventory cost 13
Axalta Coating Systems Various factors that affect product wheel 14
Axalta Coating Systems 15 Develop Tool • Extruder 7 & Extruder 8 : Black Products • Extruder 3 : Grey &White products Comparison • Transition time One week bucket Two Week bucket Product wheel model Different wheel length Comparison • Cycle stock Safety stock • Annual FPO’s Labor cost • Inventory value Annual Machine utility • Total Cost Tasks Involved
Axalta Coating Systems Tool Developed: 16 Product Wheel model Boilerplate capacity (lbs/day) 45000 Target % Uptim 85% Calc'd Min Wheel length 16 Wheel length (prod days) 20 Max batch load size 5000 Max fpo time coverage (prod days) 130 Operator hours in each test cycle 1.21 # Operators for transitions 4 Yield loss % on first bx of fpo 2% Annual FPOs 322 Annual batches 815 Annual machine utility 65% # Operators (load, ettr, test, acm) 7.3 Annual Transition hrs/ 000lb 0.20 Cycle stock (lbs) 160025 Safety stock (lbs) 104791 Labour cost $551,225 Yield loss value $45,831 Inventory value $396,865 Inventory CC $67,467 Total cost $664,523 Current # operators 9 Current annual transition hrs/000lb 0.14 Current Annual machine utility 61% Current cycle stock 238900 Current Safety stock 95967 Current labour cost $693,750 Current Yield loss $31,387 Current Inv value $507,072 Current Inv CC $86,202 Total current cost $811,339  Develop the monthly sequence of Grey/White/Black products generally manufactured at site.  For each product find Quantity to be manufactured Cleaning Time  Information collected from Planning tool Safety Stock Cost/lb Tasks involved to develop Tool
Axalta Coating Systems Weekly Analysis 17 Monthly Analysis Row Labels Sum of QTY Sum of Cleaning Count of FPO NO. Transition hrs/000 lb Days to Produce 1 147000 8 4 0.05 3.74 2 105000 24 5 0.23 3.43 3 96700 28 9 0.29 3.41 4 186000 40 13 0.22 5.97 5 242600 32 10 0.13 6.95 6 70000 4 2 0.06 1.79 7 159000 24 7 0.15 4.68 8 16000 0 1 0.00 0.37 9 158000 0 4 0.00 3.66 10 122800 24 6 0.20 3.84 11 184000 20 6 0.11 5.09 12 71000 12 4 0.17 2.14 13 48000 0 4 0.00 1.11 14 107000 32 5 0.30 3.81 15 246000 20 6 0.08 6.53 16 48000 8 4 0.17 1.44 17 104000 16 5 0.15 3.07 18 120000 24 6 0.20 3.78 19 136000 4 2 0.03 3.31 20 150000 16 7 0.11 4.14 21 87000 28 5 0.32 3.18 22 77000 24 4 0.31 2.78 23 175000 32 8 0.18 5.38 24 58500 12 3 0.21 1.85 Grand Total 2914600 432 130 0.15 85.47 Row Labels Sum of QTY Sum of Cleaning Count of FPO NO. Transition hrs/1000 lb 1 348700 60 18 0.17 2 657600 100 32 0.15 3 551800 56 21 0.10 4 401000 52 15 0.13 5 558000 68 24 0.12 6 397500 96 20 0.24 Grand Total 2914600 432 130 0.15 Current # operators 9 Current annual transition hrs/000lb 0.14 Current Annual machine utility 66% Current cycle stock 321700 Current Safety stock 259120 Current labour cost $693,750 Current Yield loss $38,032 Current Inv value $770,220 Current Inv CC $130,937 Totla current cost $862,719 Product Wheel Analysis Extruder - 3 Comparison of bucket sequencing and Wheel sequencing
Axalta Coating Systems Results: From monthly analysis we see some improvement are in Feb, March with 3 week buckets, but April worse, May improved…so not clear there’s been a sustained improvement. With Product wheel the transition rate is constant at 0.14 hrs/1000 lb. 18
Axalta Coating Systems Summary by Wheel length for E3 Overall costs look pretty flat across the various wheel lengths (savings in cost are balanced by increase in inventory) Note that both Safety stock and Cycle stock go up with wheel length Note that current # FPO’s tracks to about 40 day wheel length, although inventory is higher here…same is in Safety stock (because of longer lead times) Min wheel lengthWheel = 20 Wheel = 40 Wheel = 60 Boilerplate capacity (lbs/day) Target % Uptim Calc'd Min Wheel length Wheel length (prod days) 16 20 40 60 Max batch load size 4000 4000 4000 4000 Max fpo time coverage (prod days) 130 130 130 130 Operator hours in each test cycle 1.21 1.21 1.21 1.21 # Operators for transitions 4 4 4 4 Yield loss % on first bx of fpo 2% 2% 2% 2% Annual FPOs 584 503 289 202 Annual batches 1430 1430 1430 1430 Annual machine utility 74% 71% 62% 58% # Operators (load, ettr, test, acm) 8.8 8.7 8.1 7.9 Annual Transition hrs/ 000lb 0.13 0.11 0.06 0.05 Cycle stock (lbs) 193665 231206 434404 644840 Safety stock (lbs) 254148 284146 401844 492156 Labour cost $661,237 $649,504 $610,266 $594,313 Yield loss value $61,548 $53,091 $30,454 $21,155 Inventory value $596,853 $685,652 $1,108,257 $1,504,198 Inventory CC $101,465 $116,561 $188,404 $255,714 Total cost $824,249 $819,156 $829,124 $871,182
Axalta Coating Systems 20 On each Extruder Amount Produced = 130,000 lbs/week For 3 Extruder = 390,000 lbs/Week = 1.56 Mill lbs/Month Cleaning time savings = 0.02 hrs/1000lb = 31.00 hrs/ Month = 372 hrs/Year So implementation depends on the business strategy. From production side there are good savings. From supply chain side the inventory increases. But total cost remains the same. Bucket Sequence Current (hrs/1000lb) Product Wheel Proposed (hrs/1000lb) Wheel length(Days) Extruder 3 O.15 0.14 20 Extruder 7 0.15 0.06 20 Extruder 8 0.11 0.15 30 0.14 0.12 Average Transition Time Analysis
Axalta Coating Systems PLANNING SOFTWARE 21
Axalta Coating Systems RTE CODE RTE SEQ# FML SFX ITEM_CODE ITEM_DESC FPO NO. ATS DATE Inv Class Total FZ 0004 01 HFB624T1055 BLACK TEX AR400 000916 6/14/15CSS 20,000 E6 0002 02 PR1715000 C7605 5% MB P6040/C UF 000478 6/14/15INTMED 2,300 E6 0003 02 PR1715000 C7605 5% MB P6040/C UF 000479 6/14/15INTMED 2,300 HFNC 0015 01 72508FG200 GREEN FAST PIPE POWDER 098465 6/14/15FNC 43,200 HFNC 0016 01 72508FG200 GREEN FAST PIPE POWDER 098466 6/14/15FNC 43,200 HFNC 0012 01 72719WM055 GREEN WIRE MESH FBE 000810 6/14/15CSS 10,000 HFNC 0013 01 70014055 GREEN WIRE MESH FBE 000455 6/14/15STD 14,400 HFNC 0011 01 72514LGEN200 NAP-GARD LONG GEL RED FBE 000852 6/14/15FNC 43,200 HFNC 0009 01 PI2066 NAP-GARD REBAR BASE 000667 6/14/15INTMED 86,400 HFNC 0008 01 PI2064 REBAR FBE BASE 099604 6/14/15INTMED 30,000 HFNC 0010 01 PI2064 REBAR FBE BASE 000428 6/14/15INTMED 30,000 HFNC 0014 01 PI2064 REBAR FBE BASE 000351 6/14/15INTMED 45,000 HOU-DARK 0024 01 ELB400P9055 BLACK BEAUTY 000474 6/14/15NCS 20,000 HOU-DARK 0021 01 UFB657S0250 BLACK MAGIC II 000640 6/14/15CSS 35,000 HOU-DARK 0015 01 ELB601P9055 BLACK SNOW 000475 6/14/15STD 30,000 HOU-DARK 0023 01 HFB601S6055 CAB BLACK 000431 6/14/15STD 15,000 HOU-DARK 0017 01 PLB622S4055 EBONY LE II 000727 6/14/15STD 25,000 HOU-DARK 0025 01 SSB615H1000 HT ACE BLACK 000706 6/14/15INTMED 3,000 HOU-DARK 0026 01 PFB710S6055 SPOCK BLACK 099732 6/14/15NCS 15,000 HOU-DARK 0019 01 EFB628S9201 VACUPRIME 301 098349 6/14/15CSS 10,000 HOU-DARK 0022 01 EFB628S9025 VACUPRIME 301 098355 6/14/15CSS 5,000 HOU-DARK 0016 01 EFH641P7055 VAULT GRAY 000832 6/14/15CSS 20,000 HOU-DARK 0020 01 PFB401S6055 VULCAN BLACK 000316 6/14/15STD 15,000 HOU-COLOR 0005 01 RFG631S6250 WC CM GREEN 099147 6/14/15CSS 45,000 HOU-COLOR 0006 01 PI2000 SUN GOLD BASE 000711 6/14/15INTMED 5,000 HOU-COLOR 0007 01 HFG603S7055 HI-H0G GREEN 000849 6/14/15CSS 10,000 HOU-COLOR 0008 01 PFY627S9055 HIGH GLOSS CAT YELLOW II 000644 6/14/15NCS 4,000 HOU-COLOR 0009 01 RFK632S9055 FLEX BLUE 000568 6/14/15CSS 15,000 HOU-COLOR 0010 01 PFS641S8122 KB ORANGE III 000083 6/14/15CSS 20,000 HOU-LIGHT 0011 01 RFH752R8055 GEOTHERMAL GRAY 000642 6/14/15CSS 15,000 Products Weekly Bucket
Axalta Coating Systems Tools used for planning 23 Extruder Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Must put Functional All Rebar, CG HOG BLACK, Green Wire Mesh Vacuprime 301 Yellows Mostly ANY deco or functional. Any colors Whites and grays Hou Light small batches of deco or Hi Temp products, clears small batches of light colored deco (yellow, Oranges, red), Hi Temp Products small batches of deco or Hi Temp products, clears ANY deco or functional. Mostly black products or dark colored ANY deco or functional. Mostly black products or dark colored Can not no deco (no choppers). No Dark colors (black, dark gray, bronze…) anything except those colors due to difficult cleanings TOOL 1
Axalta Coating Systems 24 EXTRUDER 1 EXTRUDER 2 Extruder 3 extruder 4 extruder 5 EXTRUDER 1 EXTRUDER 3 EXTRU DER4 EXTRUDER 8 &7 Extruder 6 MUST PUT MOSTLY function al REBAR/CG HOG/green wire mesh Whites Vaccuprime Yellows/High temp 0009 16 BLACK TEX AR400 0004 78 C7605 5% MB P6040/C UF 0004 79 C7605 5% MB P6040/C UF 098465 GREEN FAST PIPE POWDER 098466 GREEN FAST PIPE POWDER 000810 GREEN WIRE MESH FBE 000810 000455 GREEN WIRE MESH FBE 000455 000852 NAP-GARD LONG GEL RED FBE 000667 NAP-GARD REBAR BASE 099604 REBAR FBE BASE 000428 REBAR FBE BASE 000351 REBAR FBE BASE 000474 00047 4 BLACK BEAUTY 000640 00064 0 BLACK MAGIC II 000475 00047 5 BLACK SNOW Excel tools developed for Tool 1
Axalta Coating Systems Date completed FROM Product code FROM Product Type of Test ACM, COMPATIBILITY or BOTH TO Product code TO Product Result GREEN = B/B RED =/= B/B (yes/no does not consider B/B restrictions) 11/30/2010 PFB706S4 AR400 RICH BLACK MATTE COMPATIBILITY PFB624S6 BLACK GUARD III NO 5/18/2012 PFB618T0 YGY TEXTURE ACM PFB660T1 NSN BLACK TEX YES 2/2/2011 RFB632S8 WIRE BLACK ACM RFB649S3 PONG BLACK YES 3/7/2011 RFB632S8 WIRE BLACK BOTH EFB504S0 RAVEN YES 11/30/2010 RFW693S8 FS WHITE II COMPATIBILITY RLW606S9 SANTELL WHITE II NO 11/30/2010 UFB500S9 GLOSS BLACK COMPATIBILITY UFB551S2 MATTE BLACK NO 12/20/2011 RFB632S8 WIRE BLACK COMPATIBILITY UFB655S2 MATTE BLACK II YES 1/25/2012 RFB632S8 WIRE BLACK ACM PFB401S6 VULCAN BLACK YES 11/30/2010 PFHR29S7 RAL 7037 COMPATIBILITY PFH508S5 HAZE GRAY NO 11/30/2010 RLW606S9 SANTELL WHITE II COMPATIBILITY RFW693S8 FS WHITE II NO 5/22/2012 RFB632S8 WIRE BLACK ACM HFB603S5 RAIL BLACK YES 12/2/2010 EFB206S9 BLACK SHINE COMPATIBILITY ELB601P9 BLACK SNOW YES but EXCEPT. 12/2/2010 PFH706S5 GUNSMOKE III COMPATIBILITY PFH508S5 HAZE GRAY NO 12/2/2010 PFH508S5 HAZE GRAY COMPATIBILITY NO 5/24/2012 RFB632S8 WIRE BLACK COMPATIBILITY HFB603S5 RAIL BLACK YES 12/6/2010 RFW695S8 CI WHITE II COMPATIBILITY PFW704S9 WHITE WCJ NO 12/6/2010 PFW653S9 CUSTOM WHITE III COMPATIBILITY PFW704S9 WHITE WCJ NO 12/6/2010 PI4073 FEI BRONZE II BASE COMPATIBILITY PI6003 STATUARY BRONZE BASE NO 12/6/2010 PLW602S8 POLAR WHITE II COMPATIBILITY PLW606S7 WEATHERGUARD III NO 12/6/2010 EFB617S0 RISER BLACK II COMPATIBILITY ELB400P9 BLACK BEAUTY NO 6/16/2012 RFB632S8 WIRE BLACK ACM HFB605T3 BLACK MINI TEX HAA YES 12/6/2010 PFW704S9 WHITE WCJ COMPATIBILITY RFW695S8 CI WHITE II NO 8/30/2012 RFB632S8 WIRE BLACK COMPATIBILITY PFB502S8 BLACK PEARL YES 10/19/2011 ULW401T1 WILD RICE ACM PFW623S8 BRITE WHITE YES 12/6/2010 PFW704S9 WHITE WCJ BOTH PFW653S9 CUSTOM WHITE III YES 12/9/2010 RFW695S8 CI WHITE II COMPATIBILITY PFW653S9 CUSTOM WHITE III NO 12/9/2010 PFW653S9 CUSTOM WHITE III COMPATIBILITY RFW695S8 CI WHITE II NO 1/30/2011 PFW704S9 WHITE WCJ COMPATIBILITY PFW732S8 DAYLIGHT WHITE YES 12/9/2010 PFB618T0 YGY TEXTURE COMPATIBILITY SFB607H0 WG HI TEMP BLACK YES but TGIC 12/13/2010 PI6076 BOX GRAY II BASE COMPATIBILITY HLH604S9 WC GRAY II NO 3/14/2011 PFW704S9 WHITE WCJ ACM PFW710T1 SIGNAL WHITE YES 12/13/2010 PFB680S1 COR BLACK II COMPATIBILITY UFB610S4 CASCADE BLACK NO 7/15/2011 PFW704S9 WHITE WCJ BOTH PFW510S9 SKY WHITE YES 12/13/2010 PFW500S9 GLACIER WHITE COMPATIBILITY PFW510S9 SKY WHITE NO 12/13/2010 PFW510S9 SKY WHITE COMPATIBILITY PFW500S9 GLACIER WHITE NO 11/22/2011 PFW704S9 WHITE WCJ BOTH PFW600S9 CUSTOM WHITE YES 12/13/2010 HLH604S9 WC GRAY II COMPATIBILITY PI6076 BOX GRAY II BASE NO 2/3/2012 PFW704S9 WHITE WCJ COMPATIBILITY RFW705S9 FAB WHITE YES 3/7/2012 PFW704S9 WHITE WCJ ACM PFW744S8 DAYLIGHT WHITE II YES 25 2ND TOOL Compatibility Chart
Axalta Coating Systems 1st product 2nd product 3rd product 4th product 5th product MILLENIUM GRAY II ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX BOX GRAY II BASE BOX GRAY II BASE ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX BOX GRAY II BASE 26 Product to find the sequence FOR Excel Tool for compatibility chart
Axalta Coating Systems Recommendation We should continue working this tool so that complete sequencing of products can be done with this software. 27
Axalta Coating Systems QUESTIONS / SUGGESTIONS 28

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Project

  • 1.
    HARISH KUMAR SHAHI MBA,BAUERCOLLEGE OF BUSINESS UNIVERSITY OF HOUSTON SUMMER INTERNSHIP PROJECT OPERATIONS May - August 15
  • 2.
    Axalta Coating Systems PROJECTSUNDERTAKEN DURING INTERNSHIP Worked on 3 projects during my internship.  Optimization of Extruders.  Complete analysis on Product Wheel  Development of Planning software tool 2 Analysis
  • 3.
  • 4.
    Axalta Coating Systems OBJECTIVE Find the constraints in achieving the maximum throughput.  Find the new run condition for the machines.  Analyze the increase in the Throughput (lbs/hr) in this process.  Recommendations to maintain these operation conditions in future. 4
  • 5.
    Axalta Coating Systems5 EXTRUDER 1 Date Product Name Scre w Spee d Final Feeder Speed Initial Speed (If changes were not made) Initial Throughp ut (lbs/hr) Final Thro ughp ut (lbs/h r) Increas e in Throug h Put (lbs/hr) Major Constraint Identified 27- May 72514LGE 475 235 225 2105 2105 0 Cooling belt problem: Not enough Cooling 28- May 72501 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 29- May 72500 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 30- May 7200 BRITTLE 475 250 225 2105 2400 295 Cooling belt problem: Water sprinklers not working 1-Jun FBE PIPE POWDER 475 250 225 2160 2400 240 Cooling belt problem: Water sprinklers not working 2-Jun RISER GREY III 400 300 200 1800 2300 500 Cooling belt problem: Water sprinklers not working 3-Jun GREY NAP-ROCK 475 250 180 1700 2360 660 4-Jun GREY NAP-ROCK 475 200 180 1700 1890 190 Cooling belt problem: Water sprinklers not working 5-Jun RISER GREY III 400 200 180 1860 2060 200 31-Jul RISER GRAY II 475 250 225 1940 2160 220 AVERAGE 1896 2169 273 % INCREASE IN THROUGH PUT 14% Procedure Followed 1.Look up at the daily running conditions( Feeder Speed, Screw speed). 2. What is the history of running the same product. 3.Try to increase the feeder speed and accordingly make changes in other parameters (Cooling Belt speed) 4. Identify the constraints 5. Analyze the changes the throughput.
  • 6.
    Axalta Coating Systems InitialAverage Throughput(lb/hr) Final Average Throughput(lb/hr) % Increase Extruder 1 1896 2169 14% Extruder 2 1428 1651 16% Extruder 3 1685 1807 7% Extruder 4 400 400 0% Extruder 5 448 516 15% Extruder 6 495 536 8% Extruder 7 1462 1603 10% Extruder 8 1461 1609 10% Average 10% 6 COMPARISON OF INITIAL AND FINAL THROUGHPUTS 0 500 1000 1500 2000 2500 Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Comparison of Initial and Final Throughputs Initial Throughput Final Throughput
  • 7.
    Axalta Coating Systems7 CONSTRAINT ANALYSIS Different Constraint Identified Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Cooling belt problem / Material stacks up at the break rolls 43% 0% 0% 0% 0% 0% 21% 20% Material backs up in feeder Hopper 10% 0% 71% 0% 83% 63% 32% 33% Feeder Load variations 10% 0% 0% 0% 0% 0% 0% 0% Potential to increase the Feeder Speed. 0% 40% 7% 0% 0% 13% 32% 27% Re Extrusion Material Spilling 0% 0% 0% 0% 17% 25% 0% 0% ACM/Tubs not available 38% 60% 21% 0% 0% 0% 16% 20% 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Cooling belt problem / Material stacks up at the break rolls Material backs up in feeder Hopper Feeder Load variations Potential to increase the Feeder Speed. Re Extrusion Material Spilling ACM/Tubs not available
  • 8.
    Axalta Coating Systems8 CONSTRAINTS PROPORTIONS Cooling belt problem / Material stacks up at the break rolls 12% Material backs up in feeder Hopper 42% Feeder Load variations 1% Potential to increase the Feeder Speed. 17% Re Extrusion Material Spilling 6% ACM/Tubs not available 22%
  • 9.
    Axalta Coating Systems Recommendations Find the solution for the problem of backing up of material in the hopper. Equipment modification such as Design changes in screws.  Better Cooling system. Maintenance of sprinklers Design modification  Better Communication with the operators. Need to work with engineer to develop new run conditions for the machines as per the data collected for last 3 months.  We should work on the ACMs to increase the Throughput by analyzing various run conditions. 9
  • 10.
    Axalta Coating Systems COMPLETEANALYSIS OF PRODUCT WHEEL 10
  • 11.
    Axalta Coating Systems Background PresentlyBucket sequencing is followed at the site. The products are sequenced on the weekly bucket basis as per the demand . In this process cleaning has to be done more often. This increases the productivity cost. Wheel sequencing is sequencing of products as per consistent cycle. It helps in reducing the cleaning time, inventory cost and in turn total production cost. 11
  • 12.
    Axalta Coating Systems Tounderstand if Wheel sequencing will be Beneficial? What is Product wheel? Production sequence used by a manufacturing operation when multiple products are made on a single line/piece of equipment  Consistent sequence  Repetitive time cycle 12
  • 13.
    Axalta Coating Systems Benefits Decreases controllable fixed costs  Provides framework for establishing customer order lead times  Provides understanding of relationship between transition cost and inventory cost 13
  • 14.
    Axalta Coating Systems Variousfactors that affect product wheel 14
  • 15.
    Axalta Coating Systems15 Develop Tool • Extruder 7 & Extruder 8 : Black Products • Extruder 3 : Grey &White products Comparison • Transition time One week bucket Two Week bucket Product wheel model Different wheel length Comparison • Cycle stock Safety stock • Annual FPO’s Labor cost • Inventory value Annual Machine utility • Total Cost Tasks Involved
  • 16.
    Axalta Coating Systems ToolDeveloped: 16 Product Wheel model Boilerplate capacity (lbs/day) 45000 Target % Uptim 85% Calc'd Min Wheel length 16 Wheel length (prod days) 20 Max batch load size 5000 Max fpo time coverage (prod days) 130 Operator hours in each test cycle 1.21 # Operators for transitions 4 Yield loss % on first bx of fpo 2% Annual FPOs 322 Annual batches 815 Annual machine utility 65% # Operators (load, ettr, test, acm) 7.3 Annual Transition hrs/ 000lb 0.20 Cycle stock (lbs) 160025 Safety stock (lbs) 104791 Labour cost $551,225 Yield loss value $45,831 Inventory value $396,865 Inventory CC $67,467 Total cost $664,523 Current # operators 9 Current annual transition hrs/000lb 0.14 Current Annual machine utility 61% Current cycle stock 238900 Current Safety stock 95967 Current labour cost $693,750 Current Yield loss $31,387 Current Inv value $507,072 Current Inv CC $86,202 Total current cost $811,339  Develop the monthly sequence of Grey/White/Black products generally manufactured at site.  For each product find Quantity to be manufactured Cleaning Time  Information collected from Planning tool Safety Stock Cost/lb Tasks involved to develop Tool
  • 17.
    Axalta Coating Systems WeeklyAnalysis 17 Monthly Analysis Row Labels Sum of QTY Sum of Cleaning Count of FPO NO. Transition hrs/000 lb Days to Produce 1 147000 8 4 0.05 3.74 2 105000 24 5 0.23 3.43 3 96700 28 9 0.29 3.41 4 186000 40 13 0.22 5.97 5 242600 32 10 0.13 6.95 6 70000 4 2 0.06 1.79 7 159000 24 7 0.15 4.68 8 16000 0 1 0.00 0.37 9 158000 0 4 0.00 3.66 10 122800 24 6 0.20 3.84 11 184000 20 6 0.11 5.09 12 71000 12 4 0.17 2.14 13 48000 0 4 0.00 1.11 14 107000 32 5 0.30 3.81 15 246000 20 6 0.08 6.53 16 48000 8 4 0.17 1.44 17 104000 16 5 0.15 3.07 18 120000 24 6 0.20 3.78 19 136000 4 2 0.03 3.31 20 150000 16 7 0.11 4.14 21 87000 28 5 0.32 3.18 22 77000 24 4 0.31 2.78 23 175000 32 8 0.18 5.38 24 58500 12 3 0.21 1.85 Grand Total 2914600 432 130 0.15 85.47 Row Labels Sum of QTY Sum of Cleaning Count of FPO NO. Transition hrs/1000 lb 1 348700 60 18 0.17 2 657600 100 32 0.15 3 551800 56 21 0.10 4 401000 52 15 0.13 5 558000 68 24 0.12 6 397500 96 20 0.24 Grand Total 2914600 432 130 0.15 Current # operators 9 Current annual transition hrs/000lb 0.14 Current Annual machine utility 66% Current cycle stock 321700 Current Safety stock 259120 Current labour cost $693,750 Current Yield loss $38,032 Current Inv value $770,220 Current Inv CC $130,937 Totla current cost $862,719 Product Wheel Analysis Extruder - 3 Comparison of bucket sequencing and Wheel sequencing
  • 18.
    Axalta Coating Systems Results: Frommonthly analysis we see some improvement are in Feb, March with 3 week buckets, but April worse, May improved…so not clear there’s been a sustained improvement. With Product wheel the transition rate is constant at 0.14 hrs/1000 lb. 18
  • 19.
    Axalta Coating Systems Summaryby Wheel length for E3 Overall costs look pretty flat across the various wheel lengths (savings in cost are balanced by increase in inventory) Note that both Safety stock and Cycle stock go up with wheel length Note that current # FPO’s tracks to about 40 day wheel length, although inventory is higher here…same is in Safety stock (because of longer lead times) Min wheel lengthWheel = 20 Wheel = 40 Wheel = 60 Boilerplate capacity (lbs/day) Target % Uptim Calc'd Min Wheel length Wheel length (prod days) 16 20 40 60 Max batch load size 4000 4000 4000 4000 Max fpo time coverage (prod days) 130 130 130 130 Operator hours in each test cycle 1.21 1.21 1.21 1.21 # Operators for transitions 4 4 4 4 Yield loss % on first bx of fpo 2% 2% 2% 2% Annual FPOs 584 503 289 202 Annual batches 1430 1430 1430 1430 Annual machine utility 74% 71% 62% 58% # Operators (load, ettr, test, acm) 8.8 8.7 8.1 7.9 Annual Transition hrs/ 000lb 0.13 0.11 0.06 0.05 Cycle stock (lbs) 193665 231206 434404 644840 Safety stock (lbs) 254148 284146 401844 492156 Labour cost $661,237 $649,504 $610,266 $594,313 Yield loss value $61,548 $53,091 $30,454 $21,155 Inventory value $596,853 $685,652 $1,108,257 $1,504,198 Inventory CC $101,465 $116,561 $188,404 $255,714 Total cost $824,249 $819,156 $829,124 $871,182
  • 20.
    Axalta Coating Systems20 On each Extruder Amount Produced = 130,000 lbs/week For 3 Extruder = 390,000 lbs/Week = 1.56 Mill lbs/Month Cleaning time savings = 0.02 hrs/1000lb = 31.00 hrs/ Month = 372 hrs/Year So implementation depends on the business strategy. From production side there are good savings. From supply chain side the inventory increases. But total cost remains the same. Bucket Sequence Current (hrs/1000lb) Product Wheel Proposed (hrs/1000lb) Wheel length(Days) Extruder 3 O.15 0.14 20 Extruder 7 0.15 0.06 20 Extruder 8 0.11 0.15 30 0.14 0.12 Average Transition Time Analysis
  • 21.
  • 22.
    Axalta Coating Systems RTECODE RTE SEQ# FML SFX ITEM_CODE ITEM_DESC FPO NO. ATS DATE Inv Class Total FZ 0004 01 HFB624T1055 BLACK TEX AR400 000916 6/14/15CSS 20,000 E6 0002 02 PR1715000 C7605 5% MB P6040/C UF 000478 6/14/15INTMED 2,300 E6 0003 02 PR1715000 C7605 5% MB P6040/C UF 000479 6/14/15INTMED 2,300 HFNC 0015 01 72508FG200 GREEN FAST PIPE POWDER 098465 6/14/15FNC 43,200 HFNC 0016 01 72508FG200 GREEN FAST PIPE POWDER 098466 6/14/15FNC 43,200 HFNC 0012 01 72719WM055 GREEN WIRE MESH FBE 000810 6/14/15CSS 10,000 HFNC 0013 01 70014055 GREEN WIRE MESH FBE 000455 6/14/15STD 14,400 HFNC 0011 01 72514LGEN200 NAP-GARD LONG GEL RED FBE 000852 6/14/15FNC 43,200 HFNC 0009 01 PI2066 NAP-GARD REBAR BASE 000667 6/14/15INTMED 86,400 HFNC 0008 01 PI2064 REBAR FBE BASE 099604 6/14/15INTMED 30,000 HFNC 0010 01 PI2064 REBAR FBE BASE 000428 6/14/15INTMED 30,000 HFNC 0014 01 PI2064 REBAR FBE BASE 000351 6/14/15INTMED 45,000 HOU-DARK 0024 01 ELB400P9055 BLACK BEAUTY 000474 6/14/15NCS 20,000 HOU-DARK 0021 01 UFB657S0250 BLACK MAGIC II 000640 6/14/15CSS 35,000 HOU-DARK 0015 01 ELB601P9055 BLACK SNOW 000475 6/14/15STD 30,000 HOU-DARK 0023 01 HFB601S6055 CAB BLACK 000431 6/14/15STD 15,000 HOU-DARK 0017 01 PLB622S4055 EBONY LE II 000727 6/14/15STD 25,000 HOU-DARK 0025 01 SSB615H1000 HT ACE BLACK 000706 6/14/15INTMED 3,000 HOU-DARK 0026 01 PFB710S6055 SPOCK BLACK 099732 6/14/15NCS 15,000 HOU-DARK 0019 01 EFB628S9201 VACUPRIME 301 098349 6/14/15CSS 10,000 HOU-DARK 0022 01 EFB628S9025 VACUPRIME 301 098355 6/14/15CSS 5,000 HOU-DARK 0016 01 EFH641P7055 VAULT GRAY 000832 6/14/15CSS 20,000 HOU-DARK 0020 01 PFB401S6055 VULCAN BLACK 000316 6/14/15STD 15,000 HOU-COLOR 0005 01 RFG631S6250 WC CM GREEN 099147 6/14/15CSS 45,000 HOU-COLOR 0006 01 PI2000 SUN GOLD BASE 000711 6/14/15INTMED 5,000 HOU-COLOR 0007 01 HFG603S7055 HI-H0G GREEN 000849 6/14/15CSS 10,000 HOU-COLOR 0008 01 PFY627S9055 HIGH GLOSS CAT YELLOW II 000644 6/14/15NCS 4,000 HOU-COLOR 0009 01 RFK632S9055 FLEX BLUE 000568 6/14/15CSS 15,000 HOU-COLOR 0010 01 PFS641S8122 KB ORANGE III 000083 6/14/15CSS 20,000 HOU-LIGHT 0011 01 RFH752R8055 GEOTHERMAL GRAY 000642 6/14/15CSS 15,000 Products Weekly Bucket
  • 23.
    Axalta Coating Systems Toolsused for planning 23 Extruder Extruder 1 Extruder 2 Extruder 3 Extruder 4 Extruder 5 Extruder 6 Extruder 7 Extruder 8 Must put Functional All Rebar, CG HOG BLACK, Green Wire Mesh Vacuprime 301 Yellows Mostly ANY deco or functional. Any colors Whites and grays Hou Light small batches of deco or Hi Temp products, clears small batches of light colored deco (yellow, Oranges, red), Hi Temp Products small batches of deco or Hi Temp products, clears ANY deco or functional. Mostly black products or dark colored ANY deco or functional. Mostly black products or dark colored Can not no deco (no choppers). No Dark colors (black, dark gray, bronze…) anything except those colors due to difficult cleanings TOOL 1
  • 24.
    Axalta Coating Systems24 EXTRUDER 1 EXTRUDER 2 Extruder 3 extruder 4 extruder 5 EXTRUDER 1 EXTRUDER 3 EXTRU DER4 EXTRUDER 8 &7 Extruder 6 MUST PUT MOSTLY function al REBAR/CG HOG/green wire mesh Whites Vaccuprime Yellows/High temp 0009 16 BLACK TEX AR400 0004 78 C7605 5% MB P6040/C UF 0004 79 C7605 5% MB P6040/C UF 098465 GREEN FAST PIPE POWDER 098466 GREEN FAST PIPE POWDER 000810 GREEN WIRE MESH FBE 000810 000455 GREEN WIRE MESH FBE 000455 000852 NAP-GARD LONG GEL RED FBE 000667 NAP-GARD REBAR BASE 099604 REBAR FBE BASE 000428 REBAR FBE BASE 000351 REBAR FBE BASE 000474 00047 4 BLACK BEAUTY 000640 00064 0 BLACK MAGIC II 000475 00047 5 BLACK SNOW Excel tools developed for Tool 1
  • 25.
    Axalta Coating Systems Datecompleted FROM Product code FROM Product Type of Test ACM, COMPATIBILITY or BOTH TO Product code TO Product Result GREEN = B/B RED =/= B/B (yes/no does not consider B/B restrictions) 11/30/2010 PFB706S4 AR400 RICH BLACK MATTE COMPATIBILITY PFB624S6 BLACK GUARD III NO 5/18/2012 PFB618T0 YGY TEXTURE ACM PFB660T1 NSN BLACK TEX YES 2/2/2011 RFB632S8 WIRE BLACK ACM RFB649S3 PONG BLACK YES 3/7/2011 RFB632S8 WIRE BLACK BOTH EFB504S0 RAVEN YES 11/30/2010 RFW693S8 FS WHITE II COMPATIBILITY RLW606S9 SANTELL WHITE II NO 11/30/2010 UFB500S9 GLOSS BLACK COMPATIBILITY UFB551S2 MATTE BLACK NO 12/20/2011 RFB632S8 WIRE BLACK COMPATIBILITY UFB655S2 MATTE BLACK II YES 1/25/2012 RFB632S8 WIRE BLACK ACM PFB401S6 VULCAN BLACK YES 11/30/2010 PFHR29S7 RAL 7037 COMPATIBILITY PFH508S5 HAZE GRAY NO 11/30/2010 RLW606S9 SANTELL WHITE II COMPATIBILITY RFW693S8 FS WHITE II NO 5/22/2012 RFB632S8 WIRE BLACK ACM HFB603S5 RAIL BLACK YES 12/2/2010 EFB206S9 BLACK SHINE COMPATIBILITY ELB601P9 BLACK SNOW YES but EXCEPT. 12/2/2010 PFH706S5 GUNSMOKE III COMPATIBILITY PFH508S5 HAZE GRAY NO 12/2/2010 PFH508S5 HAZE GRAY COMPATIBILITY NO 5/24/2012 RFB632S8 WIRE BLACK COMPATIBILITY HFB603S5 RAIL BLACK YES 12/6/2010 RFW695S8 CI WHITE II COMPATIBILITY PFW704S9 WHITE WCJ NO 12/6/2010 PFW653S9 CUSTOM WHITE III COMPATIBILITY PFW704S9 WHITE WCJ NO 12/6/2010 PI4073 FEI BRONZE II BASE COMPATIBILITY PI6003 STATUARY BRONZE BASE NO 12/6/2010 PLW602S8 POLAR WHITE II COMPATIBILITY PLW606S7 WEATHERGUARD III NO 12/6/2010 EFB617S0 RISER BLACK II COMPATIBILITY ELB400P9 BLACK BEAUTY NO 6/16/2012 RFB632S8 WIRE BLACK ACM HFB605T3 BLACK MINI TEX HAA YES 12/6/2010 PFW704S9 WHITE WCJ COMPATIBILITY RFW695S8 CI WHITE II NO 8/30/2012 RFB632S8 WIRE BLACK COMPATIBILITY PFB502S8 BLACK PEARL YES 10/19/2011 ULW401T1 WILD RICE ACM PFW623S8 BRITE WHITE YES 12/6/2010 PFW704S9 WHITE WCJ BOTH PFW653S9 CUSTOM WHITE III YES 12/9/2010 RFW695S8 CI WHITE II COMPATIBILITY PFW653S9 CUSTOM WHITE III NO 12/9/2010 PFW653S9 CUSTOM WHITE III COMPATIBILITY RFW695S8 CI WHITE II NO 1/30/2011 PFW704S9 WHITE WCJ COMPATIBILITY PFW732S8 DAYLIGHT WHITE YES 12/9/2010 PFB618T0 YGY TEXTURE COMPATIBILITY SFB607H0 WG HI TEMP BLACK YES but TGIC 12/13/2010 PI6076 BOX GRAY II BASE COMPATIBILITY HLH604S9 WC GRAY II NO 3/14/2011 PFW704S9 WHITE WCJ ACM PFW710T1 SIGNAL WHITE YES 12/13/2010 PFB680S1 COR BLACK II COMPATIBILITY UFB610S4 CASCADE BLACK NO 7/15/2011 PFW704S9 WHITE WCJ BOTH PFW510S9 SKY WHITE YES 12/13/2010 PFW500S9 GLACIER WHITE COMPATIBILITY PFW510S9 SKY WHITE NO 12/13/2010 PFW510S9 SKY WHITE COMPATIBILITY PFW500S9 GLACIER WHITE NO 11/22/2011 PFW704S9 WHITE WCJ BOTH PFW600S9 CUSTOM WHITE YES 12/13/2010 HLH604S9 WC GRAY II COMPATIBILITY PI6076 BOX GRAY II BASE NO 2/3/2012 PFW704S9 WHITE WCJ COMPATIBILITY RFW705S9 FAB WHITE YES 3/7/2012 PFW704S9 WHITE WCJ ACM PFW744S8 DAYLIGHT WHITE II YES 25 2ND TOOL Compatibility Chart
  • 26.
    Axalta Coating Systems 1stproduct 2nd product 3rd product 4th product 5th product MILLENIUM GRAY II ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX BOX GRAY II BASE BOX GRAY II BASE ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX ANSI 61 GRAY SAND TEX ANSI 70 GRAY SAND TEX BOX GRAY II BASE 26 Product to find the sequence FOR Excel Tool for compatibility chart
  • 27.
    Axalta Coating Systems Recommendation Weshould continue working this tool so that complete sequencing of products can be done with this software. 27
  • 28.