1. Kaizen
Team 2
Lean Manufacturing
November 9, 2015

2. Team members
 Lorena
 Sylvia
 Cathy C Facilitator: Jeff R.
 Claudia S
 Roger
 Rhonda
 Gemalyn
 Jose
 Maria N

3. Team Picture

4. Kaizen event agenda
Training
• Introduction
• - Kaizen Concepts & Process
• SPACER
• - Lean - Waste
• - Process Flow Analysis
• - Spaghetti Diagrams
• 2 teams
• Walk the process
STEPS
• TIME it takes to
complete a part at each
process
Lunch
• Floor Work
• - Process Flow Analysis
• - Spaghetti Diagrams
• Team Reports
Training
• 5S
• Total Quality
• Pull Systems
• Paper Air Plane
• Batch Process
• One piece flow
Lunch
Floor Work
• Work in your areas
and evaluate how
we can use 5S
• Team Reports
Training
• Takt Time
• Line Balancing
• Cell Design Layout
• 5S Team
• Set-up
• Staging
• Quality Team
• First piece
• In-process
Lunch
Floor Work
• Layout the
workstations
• Evaluate Agree on
the cell design
• Team Reports
Training
• “Implement”
• Create Cell
• Move benches
• Organize area
• Team evaluation
• Re-organize if
necessary
• Prepare line for a
production run on Friday
morning
Training
• TEST RUN
• Make any
adjustments
necessary
• Spaghetti and time
the new process
• Team report out
Learn Lean

5. Objectives
 Create a competitive advantage for ICS
 Heighten quality awareness within the cells
 Establish 1st piece build protocols
 Establish cell set-up / start-up protocols
 5S cell set-up and staging racks
 Introduce workforce to Lean Concepts

6. objetivos
 Crear una ventaja competitiva para el ICS
 Aumentar la conciencia de la calidad dentro de las células
 Establecer protocolos pieza construcción 1ª
 Establecer / protocolos de puesta en marcha celular
configurar-up
 Celular 5S configuración y bastidores de estadificación
 Introducir fuerza de trabajo a Lean Conceptos

7. Project Goals
 Opportunity to increase revenue
Goal Owner
 Faster throughput  30% Jeff R
 Decreased lead-time
 Higher quality yields  30 % Jeff R / Gemalyn
 Production capability  30% Jeff R
 Parts produced to FG daily

8. Objetivos del proyecto
 Oportunidad para aumentar los ingresos
Objetivo propietario
 Rendimiento más rápido 30% Jeff R
 Disminución del tiempo de entrega
 Rendimientos más altos de calidad 30% Jeff R /
Gemalyn
 La capacidad de producción 30% Jeff R
 Piezas producidas a FG diaria

9. Spaghetti

10. Team 2 Spaghetti

11. Team Spaghetti
 Travel
 Waste = Motion & Transportation
Results:
Pre: Cell: Improvement:
Total Steps: 857 10 8470% Astronomical!!
Distance Feet: 2571’ 30’ 2541’ Less Travel
Amount of Time: 50 min 15 sec 49min 45secTime Savings
Computer Trips: 12 2 88% Fewer Trips

12. Equipo Spaghetti
 Viajar
 Residuos = Movimiento y Transporte
Resultados:
Pre: Celda: Mejora:
Pasos totales: 857 / 10 8470% Astronómica !!
Pies Distancia: 2571’ / 30' 2541‘ Menos Viajes
Cantidad de tiempo: 50 min / 15 seg Ahorros 49min
Viajes informáticos: 12 / 2 88% menos viajes

13. 5S

14. 5S
 What is it?
 Cleaner work areas
 More organization
 Safer working conditions
 Less wasted time
 Efficient work processes and practices
 More available space
 Everything has a place and everything is in it’s place
SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN

15. 5S
 Qué es?
 Las áreas de trabajo más limpias
 Más organización
 Las condiciones de trabajo más seguras
 Menos tiempo perdido
 Procesos y prácticas de trabajo eficientes
 Más espacio disponible
 Todo tiene un lugar y todo está en su lugar
SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN
SORT, poner en orden, BRILLO, estandarizar, SUSTAIN

16. 5S
Example: Cell Set-up Shelves
After:
Before:

17. Teamwork
Cell Start-up

18. Integrated Cable Systems
Cell Set-up / Start-up Protocol
CHECKLIST
CLOCK IN / WORK ORDER
All operators / technicians must
Clock on to appropriate process sequence
VERIFY BUILD SHEETS:
Rev level to Work Order
Stations have copies posted
TOOLING:
All tooling is available and verified
Dispersed to stations
PARTS / COMPONENTS:
Verify parts to the build sheets
Collect any required pre-cut tubing
LABELS:
Distribute labels
PROCESS STATIONS:
Identify and tape WIP locations in the line
Set-up all stations for production then every operator / technician must
Verify incoming process for in-line inspection on every part
NOTIFY QUALITY:
Inform quality / inspection of cell start-up
FIRST PIECE VERIFICATION:
First process station operator / technician is responsible to:
Initiate & Fill out top of form including
Work Order ID / Assembly ID / Rev Level / Date
Form will flow though the line with the first assembly part
 Focused cell set-up
 Celular enfocada
puesta a punto
 More efficient
 Más eficiente
 Clear instructions
 Instrucciones claras
Checklist

19. Quality
First Piece
Verification

20. Calidad
Primera
Verificación
pieza

21. Integrated Cable Systems
Assembly Build Verification
First Piece Verification
Work Order ID Assembly ID Rev Level
CHECKLIST EMPLOYEE # INITIALS
PREP: Process complete per ICS build sheet
Employee # Initials
TERM: Crimp height measurement: ___________
Process complete per ICS build sheet Hand Tool # or Applicator #: ___________
Employee # Initials
PLUG: Process complete per ICS build sheet
Employee # Initials
TIN: Process complete per ICS build sheet
Employee # Initials
SOLDER: Process complete per ICS build sheet
Employee # Initials
LABEL: Paste 1x ea below of every label on assembly.
Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.
Attention: Paste on back of form if necessary
Employee # Initials
CLOSE: Process complete per ICS build sheet
Employee # Initials
TYWRAP: Process complete per ICS build sheet
Employee # Initials
COIL: Process complete per ICS build sheet
Employee # Initials
WINDING: Process complete per ICS build sheet
Employee # Initials
___________________: Process complete per ICS build sheet
Employee # Initials
TEST:
Process complete / Electronic Signature: ______________________________
Inspector # Initials
FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per:
customer print / specification / ICS build sheet
Approved for continued manufacture
Inspector # Initials
Date: _________________________
 Focused on quality
 Form travels along
with the first part
during the build
 Quality of the line
is signed off before
cell can proceed
with production
Checklist

22. Integrated Cable Systems
Assembly Build Verification
First Piece Verification
Work Order ID Assembly ID Rev Level
CHECKLIST EMPLOYEE # INITIALS
PREP: Process complete per ICS build sheet
Employee # Initials
TERM: Crimp height measurement: ___________
Process complete per ICS build sheet Hand Tool # or Applicator #: ___________
Employee # Initials
PLUG: Process complete per ICS build sheet
Employee # Initials
TIN: Process complete per ICS build sheet
Employee # Initials
SOLDER: Process complete per ICS build sheet
Employee # Initials
LABEL: Paste 1x ea below of every label on assembly.
Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.
Attention: Paste on back of form if necessary
Employee # Initials
CLOSE: Process complete per ICS build sheet
Employee # Initials
TYWRAP: Process complete per ICS build sheet
Employee # Initials
COIL: Process complete per ICS build sheet
Employee # Initials
WINDING: Process complete per ICS build sheet
Employee # Initials
___________________: Process complete per ICS build sheet
Employee # Initials
TEST:
Process complete / Electronic Signature: ______________________________
Inspector # Initials
FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per:
customer print / specification / ICS build sheet
Approved for continued manufacture
Inspector # Initials
Date: _________________________
 Centrado en la
calidad
 Forma transportar a
lo largo con la
primera parte
durante la
construcción
 Calidad de la línea se
firmó antes de celular
puede proceder con
la producción
Lista de verificación

23. First Piece Verification
 Quality / Inspection must
sign off completion
 Triggers the start of
production
 Form will live in the cell
during production

24. Cell Design
 Team focused on Pull over Batch processing
 Studied “One Piece Flow” with a Paper Airplane
Exercise.
 Learned cell layouts and effectiveness
 Created a “U Shape” cell as a team

25. Diseño de la célula
 Equipo se centró en Tire sobre el procesamiento por
lotes
 Estudió "One Piece Flow" con un aeroplano de papel
Ejercicio.
 Diseños celulares aprendidas y eficacia
 Creado una célula "U" en equipo

26. Cell Design

27. Cell Team
Results:
Pre: Post: Improvement:
Total Cycle Time: 30min 12min MUCH FASTER !!
FG Completed Takt: 30min 4min 650% Improvement!!
Quality: Unknown In Line Inspect Built in Quality
Labor Time: 96.9 hr act 77.2 hr 25% Labor Savings
Distance Feet: 1845’ 30’ 1815’ Less Travel
Space / Foot print ft2 14400ft2 216ft2 14,184 ft2 Savings
Parts per hour: 2 15 650% More per hour
Production Lead Time: 3 weeks 2 days Happy Customers!

28. Have Fun !!

30. The journey has
just begun
to be continued…
Continuously!

31. El viaje acaba de
comenzar
continuará…
Continuamente!