improvement kata application example in a shipyard

1. Improvement Kata Application Example in Shipyard Micro Panel Assembly Line What we did that considered impossible at thebeginning: Development of New Pattern of Welding? Updated with IK model and PDCA examples on 18 of July 2012 Tadas Puksta Lean Academy Lithuania June of 2012 Tadas Puksta, [email protected], www.leanmokykla.lt 1

2. Source: Mike Rother Improvemement Kata Handbook Tadas Puksta, [email protected], www.leanmokykla.lt 2

3. All data provided below isnt very accurate. The intention is to provide an idea and example how people think and act in Toyota Kata way. Tadas Puksta, [email protected], www.leanmokykla.lt 3

4. Western Shipyard AB More than 40 years experience in ship building Welding processes is a core processes in a factory Tadas Puksta, [email protected], www.leanmokykla.lt 4

5. How micro panels is used? Micro panel Tadas Puksta, [email protected], www.leanmokykla.lt 5

6. Challenge Challenge: Lets have micro panel in a volume construction without additional adjustment Tadas Puksta, [email protected], www.leanmokykla.lt 6

7. Micro panel lineCurrent Condition Process steps, sequence are predefined 5 operators (welders) Process time of preparation of one micro panel varies from 20 to 50 min. (because of different size and complexity) As a result - 50 200 mm twist of a panel (quality issues) Twist of 50 75% of micro panels require 200 mm rework later in a process of volume assembly in order to remove twist Rework time varies from 15 up to 120 min. Tadas Puksta, [email protected], www.leanmokykla.lt 7

8. Challenge: Micro Panel Line Lets have micro panel in a volume Target Condition construction without additional adjustment Current Condition 2012.05.01 Target Condition 2012.06.05 Process steps, sequence are predefined It should be defined via PDCA 5 operators (welders) 5 operators (welders) Process time of preparation of one micro panel Process time of preparation of one micro panel varies from 20 to 50 min. (because of different varies from 20 to 50 min. (because of different size and complexity) size and complexity) 50 200 mm twist of a panel (quality issues) 7 mm of twist 75% of micro panels require rework later in a 2 % rework process of volume assembly in order to remove twist Rework time varies from 15 min up to 120 min. 10 - 20 min. rework time System output: 10 panels assembled in volume System output: 18 panels assembled in volume construction per shift construction per shift Tadas Puksta, [email protected], www.leanmokykla.lt 8

9. Initial opinions of expertsWhat experts in welding respond to the initiative?You are wasting your time. It is impossible. We already done whats possible in past. The metal after getting temperature from welder goes twist. Tadas Puksta, [email protected], www.leanmokykla.lt 9

10. Improvement team Improvement team: Shop manager and Technical Manager. Both of them didnt know so much about welding ad no preconceptions. They try to learn Improvement Kata. 30 days of PDCA Every day 1-2 hours spend for experiments More than 20 short PDCA cycles. 18 negative results (refuted hypotheses) Tadas Puksta, [email protected], www.leanmokykla.lt 10

11. PDCA example #1 Obstacle: high temperature affect twist of metal sheetAHA moment - we learned, that sticking panel to theground didnt help so much to reduce twist (refuted hypotheses), but we 1 Hypothesis:observed high temperature If we will stick panel with X absorption in a time and weld dots to the groundthat welding sequence can before welding and we will be different in order to weld as in standard, wereduce temperature (ready expect to reduce the panel for next experiment) twist up to 15 mm As a result, the twist of the Conducting panel - 25 mm experiment Tadas Puksta, [email protected], www.leanmokykla.lt 11

12. PDCA example #2 Obstacle: high temperature affect twist of metal sheetAHA moment - we learned, that changing of welding sequence can reduce twist and observed that temperature is still 2 Hypothesis: concentrating at some If we will weld in Y sequence points, so welding (known), we expect to sequence can be better in reduce the panel twist up to order to reduce 15 mmtemperature (ready for next experiment) As a result, the twist of the Conducting panel - 9 mm experiment Tadas Puksta, [email protected], www.leanmokykla.lt 12

13. Micro Panel LineNew Current Condition New welding pattern identified 5 operators (welders) Process time of preparation of one micro panel varies from 30 to 60 min. 9 mm twist of a panel 0 % of micro panels require rework later in a process Twist of 9 mm Tadas Puksta, [email protected], www.leanmokykla.lt 13

14. Conditions for experimentingNo investment in expensive equipment and modern technologyNo expensive experts from outsideEverything is done by few local people and material they got for experiments Tadas Puksta, [email protected], www.leanmokykla.lt 14

15. ReflectionWhat did we learn?1. Challenge and achievements is a best motivator2. Target condition allow team to focus3. Daily PDCA and quick results accelerate learning process (necessary in order to make real improvements)4. Do not trust what experts tells you: lets go and test of yourselfNext target condition twist of 5-7 mm and process time 20 - 50 min, 0% rework in a volume construction Tadas Puksta, [email protected], www.leanmokykla.lt 15

improvement kata application example in a shipyard

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