Download to read offline
Uploaded byJeff Roach
Team Report Spanish English
The document summarizes the agenda and activities for a Kaizen event focused on lean manufacturing at Integrated Cable Systems. The team of 9 members worked to create a competitive advantage through establishing quality protocols, lean concepts, and designing a new U-shaped cell layout. Through the event, the team was able to significantly reduce cycle time, increase production capacity, and realize labor savings through applying 5S methodology and implementing a pull-based one-piece flow cell.
Team Report Spanish English
- 1.
- 2. Team members Lorena Sylvia Cathy C Facilitator: Jeff R. Claudia S Roger Rhonda Gemalyn Jose Maria N
- 3.
- 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 acompetitive 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 unaventaja 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 Opportunityto 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.
- 10.
- 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.
- 14. 5S What isit? 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-upShelves After: Before:
- 17.
- 18. Integrated Cable Systems CellSet-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.
- 20.
- 21. Integrated Cable Systems AssemblyBuild 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 AssemblyBuild 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 Teamfocused 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 lacélula 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.
- 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.
- 30. The journey has justbegun to be continued… Continuously!
- 31. El viaje acabade comenzar continuará… Continuamente!