island of excellence presentation
TRANSCRIPT
Island of Excellence Training AgendaIsland of Excellence Training Agenda
Safety - Video The Agenda Timeline Path to Excellence Pillar - .ppt Island of Excellence – .ppt Finishing/Converting Housekeeping - .ppt Island of Excellence – Assessment Process (Path to Excellence) Island of Excellence - Opportunities List Island of Excellence – Pad Lock Board .ppt Island of Excellence – List of Materials for LOTT Boards Island of Excellence – Crew Meeting Form Island of Excellence – Crew Meeting Expectations Island of Excellence – Action Plan Forms Island of Excellence – Tracking Results Form {Use Plant Actual}? The Certified Island of Excellence - .ppt Hand Out Certificates To Island of Excellence Attendees
Island of ExcellenceIsland of Excellence
Safety Housekeeping Results Oriented
Maintenance Continuous
Improvement Activities
Short Term Results Long Term Results
Island of ExcellenceIsland of Excellence
A Focused Reliable Method to Elevate Machine Condition and Performance to Sustainable World Class Levels
• Break away from the “Status Quo”
• No more of the “Same Old, Same Old”
Island of ExcellenceIsland of Excellence
An improvement process:• Focused events with a dedicated team• Machine condition and performance - achieve significant
results in a short period of time
Phase 1 – Manufacturing Basics• Ensure that machine and processes are safe, clean,
organized, well maintained and capable of achieving world class performance results
– Safety, Housekeeping & Results Oriented Maintenance
Phase 2 – Performance Results• Sweet Spot Analysis / Top Speed – Non Stop• Set Up Reduction• Downtime Reduction• Continuous Improvement
Island of ExcellenceIsland of Excellence
Goals:
• 1st Year - 2012- Be the best in Jet Container Company
– Machine Expectations = 75% or better (see assessment)– Performance = 100% of Process Reliability Standards
• 2nd Year - 2013– Machine Expectations = 100% or better (see assessment)– Performance = World Class
Create Dedicated TeamCreate Dedicated Team
Dedicated team for each machine:• Machine Operators• Machine Maintenance Champion• Machine Supervisor• One Manager – GM, PM, Supt, QM, PRM, SM, CSM, etc.• Facilitator – may be an outside resource• NOTE – All team members should receive Machine
Specific LOTT Training
Prework:• Machine Goals• Machine Performance Charts• Machine Specs• Top Orders
ExpectationsExpectations
Safety Housekeeping Results Oriented Maintenance Continuous Improvement Activities Short Term Results Long Term Results
Team will complete an Island of Excellence Assessment to benchmark current condition and create an Action Item List identifying opportunities to improve machine and processes
SafetySafety
Machine is configured to be as safe as possible• Guards, Curtains, Safety Signage, Organization, etc.
Safety Reliable Methods are a way of life• Standard LOTT Design, Boards & Training Procedures
• JSAs at machine and understood / followed by all
• No duct tape or baling wire on machine– these are a symptom of something that has not been corrected properly
The goal is ZERO incidents• Safety Incidents can cause unnecessary pain and suffering and reduce
machine productivity
• Most Safety Incidents occur in “Upset Conditions”
• The elimination of upset conditions will improve Safety and Productivity
• Safety must never be compromised for productivity
SafetySafety
HousekeepingHousekeeping
A Place For Everything & Everything In Its Place• Machine Area Layout – indicating proper layout and location of
LOTT Board, scrap, waste cans, tools, cutting dies, printing plates, equipment, etc
• All tools readily available with a designated place
The Machine “Sparkles”…• Clean Surfaces• Plant Colors• Proper Lighting• Deep Cleaning
Housekeeping – Machine - ExternalHousekeeping – Machine - External
Before
After
Housekeeping – Machine - InternalHousekeeping – Machine - Internal
Before
After
Housekeeping - OrganizationHousekeeping - Organization
Results Oriented MaintenanceResults Oriented Maintenance
Team approach b/w Maintenance & Operations• Machine Maintenance Champions
Maintain OEM (Original Equipment Manufacturer) Condition• Essential Equipment Care
– Housekeeping, Lubrication, Preventive Maintenance, Calibration
– don’t just repair the problem - determine root cause of failure & eliminate
– PM’s Scheduled & Completed on Time Document all Work with Work Orders Plan & Schedule all Non-Emergency Work Maintenance Planning Meeting Use History to Improve the Quality of PM’s Condition Monitoring
• All machine controls & gauges are clearly and professionally identified The ultimate objective is zero unplanned downtime
Condition MonitoringCondition Monitoring
Condition MonitoringCondition Monitoring
Continuous Improvement ActivitiesContinuous Improvement Activities
Goals• Performance Ratio, Downtime, Speed, Set Up Time, Waste, etc.
Performance Tracking• Charting at Machine• LED’s
Recognition & Accountability Crew Meetings - Action Plans
• Daily Downtime Meetings (if DT over target level)
Machine Calibration & Centerlining Top Speed - Non Stop
Phase One – Manufacturing BasicsPhase One – Manufacturing Basics
Island of Excellence Assessment• Benchmark current condition and performance• Measure Improvement
Action Plan• What needs to be done, by when and by whom• Flipcharts at machine
Crew Meetings• Follow up with Action Plan during regularly
scheduled crew meetings
Phase 2 - Top Speed - Non StopPhase 2 - Top Speed - Non Stop
Agree on Machine Capability• Machine Specs
Sweet Spot Analysis• Identify machine Sweet Spot• Identify Top 10 Orders by quantity & frequency• Choose “Focus Jobs” from Top 10 orders that
fall within the Sweet Spot• Sweet Spot Analysis results should be used by
Sales & Customer Service to better understand whether a job runs with higher or lower productivity and by scheduling to determine which machine is best for each order
Sweet Spot AnalysisSweet Spot Analysis
Width (Machine Direction)
Len
gth
(Cro
ss M
achi
ne D
irec
tion
)
0-15 15-25 25-35 35-45 45-55 55-65 65-75 75-85 95-97 97+
0-10
10-15 10
15-20 3
20-25 2 1 9
25-30 8
30-35 6
35-37 5 4
37-48 7
48+ Out of Machine Capability
Reduced Rate
Sweet Spot – Max Speed
Phase 2 - Top Speed - Non StopPhase 2 - Top Speed - Non Stop
Top Speed Non Stop• Goal is to run top sweet spot orders at top
machine speed with minimum downtime (without affecting safety & quality)
• Effective preparation is key:– Safety, Housekeeping and Preventive Maintenance must
be addressed ahead of time– Orders must be scheduled, cutting dies and printing
dies must be in good condition, and all materials must be ready to go
• Increase speed incrementally to identify issues and eliminate – keep detailed log during process – “Hit the Fast Button”
Phase 2 - Top Speed - Non StopPhase 2 - Top Speed - Non Stop
Top Speed Non Stop
• The exercise should show that significant performance improvement is possible if everything is organized effectively and machine speeds are pushed
• The challenge is to get the processes in place to be able to sustain top speed on an ongoing basis in future
Short Term ResultsShort Term Results
Safe, Clean and Organized Machine & Area
Zero Safety Incidents
100% or greater Machine Performance Ratio• Downtime - less than Process Reliability standard
• Speed - greater than standard
• Set Up Time - less than standard
Long Term ResultsLong Term Results
Single Digit Downtime• Machine & Process Downtime under 5% for Corrugators &
under 10% for Finishing
Average 75% of maximum machine speed
Single minute Set Up Time
Zero No Stock Downtime
Island of Excellence – Top Speed Non StopIsland of Excellence – Top Speed Non Stop
BEFORE
Island of Excellence – Top Speed Non StopIsland of Excellence – Top Speed Non Stop
AFTER
The Path To Excellence The Path To Excellence
Island of Excellence – Top Speed Non StopIsland of Excellence – Top Speed Non Stop
Machine Performance Ratio
0%
20%
40%
60%
80%
100%
120%
Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec
Before
After!
Your Island of ExcellenceYour Island of Excellence
Island of ExcellenceIsland of Excellence
Fries.wmv
• Have A Nice Day
• Questions or Comments?
Your QuestionsYour Questions
Contact InformationContact Information
The Box Doctor70 +Years Experience - LLCRoger & Dean Maxson475 Maplebrooke Dr. WestWesterville, Ohio 43082Office/Home 614-899-0473Cell 614-406-6145Fax 614-899-9329E-Mail: [email protected]@[email protected] Site: www.MaxsonContainerConsultants.comSkype # roger.maxson
Dean & Roger MaxsonDean & Roger Maxson