This document describes several Lean Six Sigma projects aimed at improving efficiency and reducing costs. It summarizes multiple projects including reducing packaging scrap, improving productivity in packaging and coil winding operations, reducing injection molding setup times, and implementing a warehouse management system. One project improved productivity from 240 to 331 packs per hour and reduced setup time from 30 minutes to under 5 minutes, realizing annual savings of $300,000.
Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
This webinar covers:
• How to use value stream mapping as an organizational transformation & leadership alignment tool
• How to plan for a value stream mapping activity
• The mechanics of mapping, including key metrics
for office/service/knowledge work
• How to create an actionable Value Stream Transformation Plan
It was really excited to run my First Lean Six Sigma Black Belt Project in my factory . And during the project im really great full to my honorable management . Now im posting this project for the audience of this site .
Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
This webinar covers:
• How to use value stream mapping as an organizational transformation & leadership alignment tool
• How to plan for a value stream mapping activity
• The mechanics of mapping, including key metrics
for office/service/knowledge work
• How to create an actionable Value Stream Transformation Plan
It was really excited to run my First Lean Six Sigma Black Belt Project in my factory . And during the project im really great full to my honorable management . Now im posting this project for the audience of this site .
Service revamp lean six sigma black belt projectSumit K Jha
Project- Service revamp
Type- Lean Six Sigma Black Belt Project
Outline- To improve the entire process of getting purchase orders, purchasing, manufacturing, warehousing and installation
Tools/Framework- Six Sigma concepts such as SIPOC, fish bone analysis, control charts and hypothesis testing; statistical tools, Microsoft Dynamic AX
Role- Project manager
Outcome- The successful completion of the project yielded in cost savings of INR 1.61 crores
This is Six Sigma Project sample for manufacturing company. This is helpful for green belt & black belt level projects. for more information, visit www.niqcgroup.com or www.niqcsixsigmatraining.com
What is cycle time in the manufacturing processMRPeasy
Cycle time is often confused with throughput time and takt time, but it is nevertheless a separate manufacturing performance indicator used to measure the duration of specific production processes and to get vital insight into your production efficiency.
Read more from here.
#throughputtime #cycletime #keyperformanceindicators #productionefficiency #mrpeasy #manufacturing #manufacturingsoftware #mrpsystem #erpsystem #manufacturingprocess
Recorded webinar: http://slidesha.re/1iJ2ZWu
Subscribe: http://ksmartin.com/subscribe
Purchase the book: http://bit.ly/VSMbk
This webinar presents case studies for several client engagements that involved value stream mapping. For each case, you'll learn:
• What the driver was for value stream improvement.
• What the planning process consisted of.
• The discoveries and challenges that surfaced—and the shifts that occurred—during the 3-day activity.
• Transformation results.
During the webinar, Karen also answers participant questions about facilitation, transformation plan ownership, team composition, going to the Gemba, and collecting data that's not easily measured.
For managing your lean manufacturing waste, you need to utilize our PPT layout on 8 lean wastes PowerPoint presentation slides which will help you in describing the elements of lean waste for your manufacturing unit. You can use this presentation slide to define every lean waste with its effects on the business performance. Describe each lean waste on PPT image which are known as the defects, excess processing, over production, waiting, inventory, moving, motion, and the last one named as non-utilized talent which is known as the management waste. You can further use this PPT template to analyze your current business production model and convert the same into the reconstituted one to make more profits for the business. So now simply click on the download link below and start working on this accurately crafted 8 lean wastes PowerPoint image to manage the lean manufacturing waste for your potential audiences. Thus start right now. Handle any hiccups that come along with our 8 Lean Wastes Powerpoint Presentation Slides. It helps iron out the creases.
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
Value Stream Transformation: Achieving Excellence through Leadership Alignmen...TKMG, Inc.
To subscribe: http://ksmartin.com/subscribe
To purchase the book: http://bit.ly/VSMbk
These are slides from a talk given on 1/8/14 in San Diego, California at SME Connect's Operations Roundtable.
Too many organizations today suffer from silo-centric behavior and intra-organizational conflict. And yet most don’t understand what’s holding them back from achieving outstanding performance. This is where Karen Martin’s new book Value Stream Mapping comes into play.
Value stream mapping can unleash the full potential of an organization and deliver greater customer value, increased profit margins, and create fulfilling work environments.
In this talk, Karen discussed how to:
• Prepare and engage your leadership team in the transformation process
• Gain a deep understanding about your current work systems and the related barriers to delivering value
• Design a future state that enables outstanding performance on all fronts
• Adopt a new design and lay the foundation for continued improvement
More Information:
https://flevy.com/browse/business-document/lean-manufacturing-160
BENEFITS OF DOCUMENT
Learn how to eliminate waste to save time and make more money.
Learn how to apply simple Lean methods and tools in the workplace to improve productivity and quality.
DOCUMENT DESCRIPTION
Lean is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the key concepts and principles of Lean
2. Acquire knowledge on the common Lean methods and tools and their applications to eliminate waste and create more value for customers
3. Identify ways to develop "Kaizen eyes" to look for improvement opportunities
4. Describe the various Lean roles
5. Define the critical success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Thinking
- The case for Lean Manufacturing
- Where did Lean originate?
- Toyota's philosophy
- Lean adoption in various environments
- Impact of Lean principles in industry
- Lean applications in manufacturing, process and service industries
- What is Lean?
- What Lean is not
- Traditional thinking versus Lean thinking
- Traditional culture vs. Lean culture
- Lean management framework
- Lean and six sigma
- Benefits of Lean manufacturing
Got a question about this presentation? Email us at support@flevy.com.
Service revamp lean six sigma black belt projectSumit K Jha
Project- Service revamp
Type- Lean Six Sigma Black Belt Project
Outline- To improve the entire process of getting purchase orders, purchasing, manufacturing, warehousing and installation
Tools/Framework- Six Sigma concepts such as SIPOC, fish bone analysis, control charts and hypothesis testing; statistical tools, Microsoft Dynamic AX
Role- Project manager
Outcome- The successful completion of the project yielded in cost savings of INR 1.61 crores
This is Six Sigma Project sample for manufacturing company. This is helpful for green belt & black belt level projects. for more information, visit www.niqcgroup.com or www.niqcsixsigmatraining.com
What is cycle time in the manufacturing processMRPeasy
Cycle time is often confused with throughput time and takt time, but it is nevertheless a separate manufacturing performance indicator used to measure the duration of specific production processes and to get vital insight into your production efficiency.
Read more from here.
#throughputtime #cycletime #keyperformanceindicators #productionefficiency #mrpeasy #manufacturing #manufacturingsoftware #mrpsystem #erpsystem #manufacturingprocess
Recorded webinar: http://slidesha.re/1iJ2ZWu
Subscribe: http://ksmartin.com/subscribe
Purchase the book: http://bit.ly/VSMbk
This webinar presents case studies for several client engagements that involved value stream mapping. For each case, you'll learn:
• What the driver was for value stream improvement.
• What the planning process consisted of.
• The discoveries and challenges that surfaced—and the shifts that occurred—during the 3-day activity.
• Transformation results.
During the webinar, Karen also answers participant questions about facilitation, transformation plan ownership, team composition, going to the Gemba, and collecting data that's not easily measured.
For managing your lean manufacturing waste, you need to utilize our PPT layout on 8 lean wastes PowerPoint presentation slides which will help you in describing the elements of lean waste for your manufacturing unit. You can use this presentation slide to define every lean waste with its effects on the business performance. Describe each lean waste on PPT image which are known as the defects, excess processing, over production, waiting, inventory, moving, motion, and the last one named as non-utilized talent which is known as the management waste. You can further use this PPT template to analyze your current business production model and convert the same into the reconstituted one to make more profits for the business. So now simply click on the download link below and start working on this accurately crafted 8 lean wastes PowerPoint image to manage the lean manufacturing waste for your potential audiences. Thus start right now. Handle any hiccups that come along with our 8 Lean Wastes Powerpoint Presentation Slides. It helps iron out the creases.
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
Value Stream Transformation: Achieving Excellence through Leadership Alignmen...TKMG, Inc.
To subscribe: http://ksmartin.com/subscribe
To purchase the book: http://bit.ly/VSMbk
These are slides from a talk given on 1/8/14 in San Diego, California at SME Connect's Operations Roundtable.
Too many organizations today suffer from silo-centric behavior and intra-organizational conflict. And yet most don’t understand what’s holding them back from achieving outstanding performance. This is where Karen Martin’s new book Value Stream Mapping comes into play.
Value stream mapping can unleash the full potential of an organization and deliver greater customer value, increased profit margins, and create fulfilling work environments.
In this talk, Karen discussed how to:
• Prepare and engage your leadership team in the transformation process
• Gain a deep understanding about your current work systems and the related barriers to delivering value
• Design a future state that enables outstanding performance on all fronts
• Adopt a new design and lay the foundation for continued improvement
More Information:
https://flevy.com/browse/business-document/lean-manufacturing-160
BENEFITS OF DOCUMENT
Learn how to eliminate waste to save time and make more money.
Learn how to apply simple Lean methods and tools in the workplace to improve productivity and quality.
DOCUMENT DESCRIPTION
Lean is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the key concepts and principles of Lean
2. Acquire knowledge on the common Lean methods and tools and their applications to eliminate waste and create more value for customers
3. Identify ways to develop "Kaizen eyes" to look for improvement opportunities
4. Describe the various Lean roles
5. Define the critical success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Thinking
- The case for Lean Manufacturing
- Where did Lean originate?
- Toyota's philosophy
- Lean adoption in various environments
- Impact of Lean principles in industry
- Lean applications in manufacturing, process and service industries
- What is Lean?
- What Lean is not
- Traditional thinking versus Lean thinking
- Traditional culture vs. Lean culture
- Lean management framework
- Lean and six sigma
- Benefits of Lean manufacturing
Got a question about this presentation? Email us at support@flevy.com.
For many businesses, getting the material from suppliers on time is a very important factor. This will decide their delivery to customers on time. As many companies in North America are procuring from China, it is all the more essential that the On Time Delivery is controlled efficiently. This presentation discusses the ways and means companies con control the On Time Delivery Metrics. This presentation also talks about a system that is common for all the trading partners and one in the cloud.
Lean six sigma - Waste elimination (Yellow Belt)Abhay Yadav
Lean Six Sigma is a methodology that relies on a collaborative team effort to improve performance by systematically removing waste; combining lean manufacturing/lean enterprise and Six Sigma to eliminate the eight kinds of waste (muda): defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
summary of 16 Lean Six Sigma improvement projects in manufacturing, bio-manufacturing, supply chain
including 2 machine safeguarding . Total savings over $8Mil
This is Profile Presentation for Operational Excellence / Lean Consultant / Leader , Industrial Engineering Lead .
11 Years Extensive knowledge and experience of Mfg. / corporate Functions
in Manufacturing & Operational Excellence.
Exposure of diff. Industries (Automobile , Air Conditing Mfg, Electronics , Oil
and Gas , Aerospace
Demonstrated ability to lead large scale Cost Saving projects with multifunctional and technical capabilities (i.e Kaizen Drive , Zero Defect Strategy Implementation , World Class
Manufacturing Best Practices Implemenation , DOJO Training center Installation
, OEE Improvements , Productivity Improvement , Consumable cost Reduction ,
WIP Reduction , Rejection Reduction , 5-S Improvement , Mfg. excellence , Low
cost Automation & Technology Upgradtion etc.)
Ability to pick up knowledge of the clients business, new technology areas,
new processes/methodologies and apply these changes in the day-to-day
working of the systems organisation
Techno-Managerial Scope :- Responsible for planning, organizing,
managing and executing projects from beginning to end with Team
Initiate and Planning for Plant Budget and compile Group Company Budget
along with Finance Team technically
Worked with Indian, Japanese , German , US , Norway team on diff. projects
Won 15+ Awards in SGA & QCC Convention (Internal and External) i.e ACMA/CII/QCFI/STQM/SCGA
Having Extensive knowledge and experience of 3 Company New Plant
Installation , 13 Manufacturing Section Installation , 180+ New Product Development in Diff. Industry
Deployed Lean Manufacturing in fabrication of Exhaust After Treatment System Rack made for VOLVO / Mack Trucks used Lean to increase productivity by 50% and Six Sigma
methodology to resolve complex design issues, improve quality controls for sustained improvement
Overview of Lean Manufacturing types of production , comparison between Batch vs Continuous Flow , how to convert batch to continuous flow and the savings
1000 TON TRANSFER PRESS SAFE WORK PROCEDURE ;DIE SETUP/CHANGEOVERJulian Kalac P.Eng
The reviewer has developed a proper Safe Work Procedure for die changeovers and die setups, which lists the proper steps to be taken to lock out the press flywheel by locking out the master stop, and how to verify zero energy state.
Legal Aspects of FMEA, overview of Canadian Law,
Due Diligence vs Negligence, Criminal Negligenced and what everyone needs to know about duty of care
www.6sengineering.com
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Planning Of Procurement o different goods and services
Lean Six Sigma Projects
1. Page 1 of 5
Examples of Lean Six Sigma projects
Scrap Reduction ($250K annual savings)
(BLACK BELT CERTIFICATION PROJECT )
Project involved over 40 people, mechanics, electricians, supervisors, lead hands, operators, across 4 shits
Project was completed in 8 months
Problem Statement: Packaging scrap was 2.4%
Objective to reduce scrap from 2.4% to 1.2%
Measure Phase tools: Detailed PFD, X-Y matrix, Gauge R&R were used to gather data
Significant factor: DOE revealed baskets style cartons were significant factors in overall Finishing scrap
Improvements: modified tooling on turn section of gluer, replacing pneumatic cylinder with load cell for better carton control, IMPLEMENTED 5S using SHADOW BOARDS, developed SOP and standardized it.
Control Plan: error proofed critical settings and implemented regular hourly SPC checks
Lean Start-Up and development (estimated savings =$300K/year)-- Alcan Packaging (2011)
Project Objective: Reduce floor space by 30% by implementing LEAN principles into diverse culture
Led team of 20 senior technicians and tool and die makers
LEAN TASKS COMPLETED:
o VALUE STREAM MAP OF CURRENT AND FUTURE STATE PROCESSES
o TAKT TIME & Cycle Time Analysis
o Waste reduction
o 5S
o Lean Training
Results:
o New layout with 40% less space utilized
o Reduced inventory levels by 30%
o 280 Employees trained on LEAN principles
o Visual aids such as: white boards, Quality Alerts, Set-Up instructions
Lean - Packaging Productivity Improvement ( $250K/Year savings)
FGF Brands Foods
Project Objective: Improve productivity from current 240packs/Hr to 310 packs/Hr
Led Project consisting of 60 people across all 3 shifts
BOSCH Packaging was main bottleneck with lengthy set-up times and downtime due to machine utilization
Improvements: Developed CURRENT STATE VALUE STREAM MAP, identified areas of WASTE, developed FUTURE STATE VALUE STREAM MAP, implemented 5S across all shifts, trained all set-up operators and lead hands on basic Lean principles, implemented SMED (Single Minute Exchange Die), developed standardized SOP’s for set-up/change-over, implemented 5s and shadow boards for all tooling storage
Results:
o Improved productivity from 240 packs/Hr to over 331 packs/Hr,
o Reduced Set-Up Time from 30 min to under 5 min
o Reduced waste from 14% to under 3%
Savings: $300K/Year in OEE improvement (machine utilization and direct labour absorption)
2. Page 2 of 5
Injection mould set-up reduction project --($500K/annual savings)
Problem Statement: 22 injection moulds ranging from 93 weeks new to moulds over 10 years old), varied in sizes & capacities, had set-up/changeover times from 4-6hrs, resulting over $500K machine inefficiencies and productivity losses
Project Involved over 50 tool and die makers, lead process operators, lead hands, supervisors
Objective: Reduce the set-up time from 6hrs to under 2hrs
Significant Improvements: over 4.5hrs of Set-Up Time was reduced by the following IMPROVEMENTS:
o Implemented SMED principles, with 5S SHADOW BOARDS, standardized tool carts, SET-UP SOP
o New water manifolds with shorter hoses and different IN/OUT connectors
o Standardized bolt lengths and utilized quick-connect clamps
o Interchangeable inserts and standardized back plates with different hole pattern
o Standardized Mould kits & implemented shadow boards
o Documented SOP and validated set-up/changeover on different shifts
These improvements resulted in over $500K annual savings
Magnum 2000 (TS-16949) Lean/Quality initiative---Summer 2009
Problem Statement:
1st time yield quality was at 62%
Led team of 30 people, operators, QA Inspectors, Lead Hands, Operators
Used 100% inspection to sort out defects in a machining operation
Premature Tool wear causing defects and downtime
Poor process flow and scheduling issues causing “RUSH” orders and panic mode
Rotary Transfer Machines:
• 16 Station Hydromat CNC
• Buffoli Transfer Machine CNC
• Hydromat - 10 Station
• Hydromat - 12 Station
Other Equipment:
• In-feed and thru-feed grinding equipment
• Durr parts washer
• Full chip and oil recovery systems
• Fully integrated MRP system
Improvements:
Developed VSM of current process and reviewed NVA for waste reduction
Implemented 5S in all machining area so that tool locations and spares were easily located and replaced when worn
Implemented in-process sampling checks based on AQL of 0.4 (99.6% confidence level) using GO/NO-GO gauges, vernier measurements
Set-up and Implemented SPC for in-process checks which allowed operators to monitor trends and adjust tooling as needed before it’s too late
Redesigned tooling for a 16 station CNC HYDROMAT which reduced premature tool wear by 25%
Developed & Implemented Preventative Maintenance procedures which reduced downtime by 30%
Designed Rough Grinding and Finish Grinding process parameters for machining water pump bearings achieving surface finishes of 0.1-0.2μm Ra (4-8 μin) consistently
Eliminated 100% inspection
Validated Testing through Reliability studies and implemented statistical process controls which reduced leak test failures from 14% to less than 0.5% improved packaging productivity by 32%
3. Page 3 of 5
GENERATOR COIL EFFICIENCY IMPROVEMENT (savings $800K/year)
Voith Hydro
Project Objective: Improve Current State Coil winding operation by 30% (28 Coils to 40 Coils/Day)
Project involved 3 shifts over 80 UNION WORKERS
Current Process Limitations: Direct Labour underutilized (65%) and bottleneck process Final Taping has MOL restriction on 4Hr/shift Max exposure time
Improvements: Developed Lean Flexible work Cell, Cross-Functionally trained all operators on Final Taping, developed rotation schedule to ensure every 2hrs Final Taping Operators are rotated, implemented internal KANBAN for pre-staging material and implemented 5S to reduce Non-Value add time (walking around looking for tools)., trained all set-up operators/lead hands on basic Lean principles
Results:
Improved productivity from 27 to 40 Coils/day
Increased Direct Labour Utilization from 65% to over 80%
Reduced floor space by 30%
Reduced WIP by 40%
5. Page 5 of 5
Flexo Efficiency improvement project ($600K annual savings)-- MeadWestvaco Packaging
Problem was poor productivity (15Kpcs/hr)
Objective was to improve Flexo Print Cut efficiency by 30% (from 15k pcs/hr to 20k pcs)/hr
Significant factors Die Cutting, Ink transfer, Varnish, & Carton type
Improvement: DOE used to optimize printing process parameters such as: Ink density & viscosity, Anilox density, Varnish viscosity & improved die set-up time
Implemented SPC checks part of the Control plan.
Warehouse Management System (WMS) project–(over $800K/annual savings) ---MeadWestvaco Packaging,
Managed a complex Supply-Chain project between MWV Paper Mill/Sales/Marketing & Coco-Cola purchasing, on improving on time delivery, increasing sales and reducing storage time of FG cartons for Coca Cola
Objective: increase Coca-Cola carton turnover rate by 30% & reduce warehouse space by 200,000 ft ²
Project was completed in 11 months
Improvements: WMS (Warehouse Management System) implemented with full automated KANBAN of Coca-Cola cartons allowing Coca Cola full access to view our warehouse inventory and give us signals when to start producing new cartons using colour codes for SKU inventory levels, Green=Don’t produce, Yellow-start, Red=late
Realized savings: on-time deliveries improved from 92% to 99.5% within 3 month, and warehouse space by 170,000ft². The but a new project was launched between MWV sales/marketing and Coca Cola purchasing to increase carton revenue (see below for details)
Sales & Coca-Cola carton turnover -part of the WMS project–(over $300K/annual savings
Problem: Graphics design on Coca Cola cartons took too long, resulting long carton development time and lack of input from MWV Sales/Marketing and Graphics
Objective: increase Coca-Cola sales by 40% and carton turnover rate by 30%
Improvement: MWV Graphics designers to be involved in the preliminary carton design and sales to use VOC (Voice Of the Customer) to visit and survey Coca Cola plants for their feedback