Download - Officina Delle Operation Vst Roller Lttt V2
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Caterpillar Mec-Track
MAKING SUSTAINABLE PROGRESS POSSIBLE
Officina delle Operation Novembre 2012
Value Stream Transformation Flusso Rulli LTTT
Team Leader: Benedetti Giancarlo Logistic Manager CPIM Certified
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
• Qual’è l’uscita di emergenza più vicina?
• Dov’è l’estintore ?
• Dov’è la cassetta di pronto soccorso ?
Sicurezza Un Impegno Quotidiano
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Chi è la Mec Track
Bazzano Total Area: 394,397 Square Ft
Covered Area: 186,205 Square Ft
Employees: 246
Castelvetro Total Area: 150,055 Square Ft
Covered: 78,038 Square Ft.
Employees: 36
San Eusebio Total Area: 43,055 Square Ft.
Covered: 16,145 Square Ft.
Employees: 38
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Caterpillar Undercarriage – Cosa produciamo
Rollers
Carrier Rollers
Idlers
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
TTT Rollers (D3 to D11) HEX Rollers (315 to 390)
TTT Idlers (D6) LHEX Idlers (345 to 390)
MTTT Carrier Roller (D6 to D7)
TTT Shaft (D6 to D11)
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Progetto VST per Large Excavators Q1 2012
Progetto VST per Large Tractors M9 Q4 2011 M11 Q3/Q4 2011
Progetto Paint: approvare RFI per verniciatura VS02 Q1 2012
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
This project will support the implementation of the Future state creating a flow for the production of the LTTT rollers in order to reduce the reduce the Total Cycle Time and Increase overall capacity This is fully aligned with the CSF Velocity
Y1 Reduce LTTT Rollers TCT ( Turning +Assembly) Y2 Increase total internal capacity to align to machine capacity
X: Create a detailed, process by process, VSM for LTTT rollers To be used in subsequent project for Redesign Mec Track lay out for LTTT
In Scope: Production Process flow for LTTT Rollers, components replenishment process for LTTT.
Reengeenering of the assembly line
Out of Scope: Heat treatment, component supply, paint and shipping
The actual Cat Mec Track lay out doesn't support a lean flow.This creates excess inventory and transportation, that are the main waste on the process.Creating a more lean flow in order to reduce the TCT.
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
M11
Focus Progetto
M9
Verniciatura Verniciatura
A7 A5
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Analisi attività per linea OP1 Collo di bottiglia
OP1 Collo di bottiglia D10 OP2 collo di bottiglia D11
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Ricerca delle opportunità sul Processo A5-M9 (VS5)
Attesa OP Tornio
Attesa + trasporto
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Ricerca delle opportunità sul Processo A7-M11 (VS7)
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Individuato modifiche tecnologiche
VS5 ; nuova stazione avvitatura
VS7: Pallettizzatore automatico
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Miglioramento potenziale
Possiamo ridurre il tempo STD , aumentando l’output delle linee del 25%
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Valutato anche l’aspetto sicurezza ed ergonomia
Measure
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Individuato criticità per gestire l’implementazione Rompere il concetto di appartenenza al reparto
Differenza di trattamento tra i reparti
Diversi responsabili
Individualismo rispetto a lavoro di squadra
Mi state chiedendo di fare di piu’
Operatori non coinvolti nelle scelte
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
STRATEGIA DI IMPLEMENTAZIONE
Lancio di due RIW
Scopo: Definire e testare gli SW
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Rianalizzato attività per linea OP1 Collo di bottiglia
OP1 Collo di bottiglia D10 OP2 collo di bottiglia D11
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Definito il lay out bordo linea
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Creato SWS per i 3 operatori
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Generate piu’ di 50 idee di miglioramento
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Comunicazione agli RSU
Costanti aggiornamenti in particolare rivolti a verificare la parte ergonomica
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Risultati di produttività interna
25% di miglioramento
dimostrato su capacità e
lead time
CATERPILLAR CONFIDENTIAL: GREEN
Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Continuiamo a lavorare per raggiungere il target monitorando l’OEE
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Cosa abbiamo imparato
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow
Abbiamo anche imparato che..
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Steel Products Remanufacturing & Components Division
Caterpillar: Confidential Yellow