kaizen event final report
TRANSCRIPT
C O N S U L T I N G
Kaizen Event Final ReportARTURO BOLAÑOS, L EAN COACH & S I X S I GMA BLACK BELT
Why are we implementing Operational Excellence?
Expectations from Participants
Before Pictures
Current State of Assembly Shop
What do you see?
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Current State Floor Layout with Spaghetti Diagram
16' 6" x 25' 0" 16' 6" x 25' 0"
Room
16' 6" x 25' 0"
Room
16' 6" x 25' 0" 16' 6" x 25' 0"
Room
8' 9.5" x 25' 0"
Room
3' 0.25" x 25' 0"
Computer Workstation
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Wir
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Wir
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Wo
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Ta
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WIP
W
ork
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Inve
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Ra
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Build ROCWork Table
Inve
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Wo
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Ta
bleIn
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Inve
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Back Panels Tool Box
Inventory Rack
Wiring Panel & Install ROC
Work Table
#1
#2
#3a
#4
Tool Box
Back Panels Inventory Rack#4aFerral Process
Work Table
#3
Wiring Panel & Install ROC
Work Table
Wiring Panel & Install ROC
Work Table
#5#5
#5
#5a
Wiring Panel & Install ROC
Work Table
Tool Box
#5
#5a
#6
Wire RackInventory Cabinets
Inventory Cabinets
Inventory
Inv
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Tool BoxBack
PanelsBack
Panels
Inv
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Inventory Inventory
InventoryInventory E
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Pcs
Find the problem areas and the metrics before the Kaizen event.
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Before Metrics
KAIZEN EVENT GOALSIMPROVEMENT METRICS BEFORE KAIZEN GOALS FOR KAIZEN
Cycle (Build ) Time 14.8 Hrs. 10.0 Hrs.
% Complete Rate 90.0%* Over 95%
Travel Distance 4162 feet 75% Reduction
Safety Issues 2 0
5S Score - Percent 30% 80%
Find the problem areas and the metrics before the Kaizen event.
*Three month average from Aug, Sept and October
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Takt Time Calculation
Customer Demand 64 units per monthCustomer Demand 16 units per weekCustomer Demand 3.2 units per day
Available Time 8 Hour shift 480 minutes start endBreaks 30 minutes 7:00 AM 16:00Clean up 10 minutesCalculated 8 hours 440 minutes
Takt Time Available Time/Customer DemandCalculated Takt Time 137 minutes
Calculated Customer Demand from previous three months data.
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Current State with 8 Hours Shift
The calculation reflect a 2 ½ week study of the Line. The Pan Assembly and Wire Panel/ ROC are the constraints with a total cycle time of 14.8 hours.
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Cut Wire BuildHarness
FerrelProcess
PanAssembly
Build ROC WirePanel/Install
ROC
QualityCheck
IntegratePanel
EOL Tester Pack
Line BalancingCurrent State
Cycle Time Takt Time
137 Minutes
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Current Metric
Monthly Completion
74.3
3 month Completion Rate Sept, Oct, Nov.
74.6 90
121.3
The Graph to the left is the data collected from weekly Completion Rate per panel. We collected data from Sept to October and took an average.
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Training Pictures
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Brainstorming The Brain Storming with 3M Post it's a tool used to sort through the brainstorm ideas from the team.
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Value GraphThe Value Graph is a tool used to sort through the brainstorm ideas from the team.
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Implementation PlanAn implementation plan is a plan put into affect to make a change. It is a detailed project that outlines any changes made and explains how the changes will come about.
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During Kaizen
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During Kaizen
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Future State Floor Layout with Spaghetti Diagram
16' 6" x 25' 0"
16' 6" x 25' 0"
Room
16' 6" x 25' 0"
Room
16' 6" x 25' 0" 16' 6" x 25' 0"
Room
8' 9.5" x 25' 0"
Room
3' 0.25" x 25' 0"
Computer Workstation
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Wir
e R
ack
sKITS, Built ROC, Prewired
Tool Box
Wire Harness Inventory Rack
Pan Assembly
Tool Box
Ra
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du
it, P
an
Ra
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Wiring Panel & Install ROC
Work Table Quality Check
Wire Rack
Computer
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Wire Assembly Work Table
Hardware Cabinet
Misc Ribbons Cabinent
Pan Assembly
E
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Daniel’sTool Box
ClaudiaTool Box
Don’s Tool Box
#1
#3
#3
#4 #5
EOL tester
#9Finish Goods
Finished Goods
Finish Goods
Wir
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Build & Wire ROCWork Table
#2
Wiring Panel & Install ROC
Work Table #4
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Wire & I/O Assembly
Work Table
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teria
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Wire Racks
Pa
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I/O
, In
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One -Off
Wire & I/O Assembly
Work Table
Asset Team Area
Connoco/Marathon Line#1
#6
#7
#8
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Future State with 8 Hours Shift
The calculation reflect with a Relayout of the line and deploying the employees to the bottlenecks to reduce the total cycle time to 9.2 hours.
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Wire Harness Build ROC Pan Assembly WirePanel/Install
ROC
Quality Check Integrate Panel EOL Tester Pack
Relayout Line BalanceFuture State
Cycle Time Takt Time
137 Minutes
Combined three operations to make
one.
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104.5111
89
119
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44
8 9
0
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60
80
100
120
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Wire Harness Build ROC Pan Assembly WirePanel/Install
ROC
Quality Check Integrate Panel EOL Tester Pack
Relayout Line BalanceFuture State
Cycle Time Cycle Time Takt Time
137 Minutes
Future State with 8 Hours Shift
Further improvements on the line to reduce bottleneck in the Pan Assembly and Wire Panel/Install ROC to total cycle time of 8.3 hours
Reduction of 48 minutes from
process Additional Savings of 23 minutes by
moving wire harness to Wire
Harness Area
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After Pictures
A vision of how our line may look after the Kaizen Event
What do you see?
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Follow-up ActionsProposed Kaizen Event
When Target Date Responsibility Completed
Verify 5S Visual Management Board is installed One week after event 12/18/2009 Team Leader Open
Verify the Pre-Kaizen 5S Audit has been posted One week after event 12/18/2009 Kaizen Leader Audit Completed
Verify the Cleaning Plans have been posted. One week after event 12/18/2009 Team Leader Completed
Perform 5S Audit using Checklist Two Weeks After 1/14/2010 Kaizen Leader Completed
Standard Work for RAS Line Two Weeks After 1/14/2010 Kaizen Leader Completed
Traing supervisor on cleaning plan Two Weeks After 1/14/2010 Kaizen Leader Completed Buy 3 Level 2 x 6 foot shelve for built ROC
Two Weeks After 1/14/2010 Scott Nicely CompletedAssemble 3 Level 2 x 6 foot shelve for built ROC
Two Weeks After 1/14/2010 Dean CompletedComputer to make tags or lables for wire harness Two Weeks After 1/14/2010 Scott Nicely Completed
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After Metrics or results
The Graph to the left is the data collected from weekly Completion Rate per panel. We collected data from Sept through 3rd Week of January.
Kaizen Events were held on Dec 12 & 22 and affected the completion rate. The line started Stress Testing the of WK 1/23.
74.3 74.6
121.3
71.8
97.8
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Monthly Completion Completion
Weekly/Monthly RAS ShopCompletion Rate Delivery
Perc
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For the month of January the average completion rate is 97.8%. Exceeding the 95% of monthly goal.
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After Metrics or results
KAIZEN EVENT GOALSIMPROVEMENT METRICS
BEFORE KAIZEN
GOALS FOR KAIZEN AFTER KAIZEN
% IMPROVEMENT
Cycle (Build ) Time 14.8 hrs. 10 Hrs. 9.2 37.8%Completion Rate per month (%) 90%* 95% 97.8%** 7%
Walking Distance 4162 feet 50% reduction 114 feet 97.2%
Safety Issues 2 0 0***
5S Score - Percent 30% 80% 66% 62.5%
*Three month average from Aug, Sept and October.
** Monthly average from Jan 2010.
*** Safety issue eliminate using A-Frame.
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Kaizen Team
The picture of the entire Kaizen Team that participated in the two Kaizen Event. Starting in the back row right is Daniel Enriquez, Felix Hughes, Carlos Silva, Becky Taylor, Don Clark, and Alex Trujio. Starting the front row begins with Dean Holmes, Patricia Stevenson, Claudia Riojas, Tim Potter, and Kaizen Instructor Arturo Bolanos.
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A proven results oriented bilingual leader with manufacturing and transactional experience. Lead the development, implementation and performance of a process improvement system for companies in Oil & Gas, Power Generation, Automotive Electronics, Semiconductor, Medical Device, and Hot Spas.
Specialties: • Provide LEAN and Six Sigma Training to Senior Management and Supervisors.• Lead, executed, tracked and report high impact projects using, PDCA
methodologies.• Deliver formal training in Six Sigma, LEAN, and Continuous Improvement
methodologies.• Coordinate with Process Owners in development of Value Stream Maps and
Process Mapping.• Provide Project Management for LEAN and Six Sigma projects.• Deliver Kaizen Leader and LEAN Facilitator Training throughout US, UK, &
Switzerland.• Lead, coached and mentor in Lean & Kaizen Events within Manufacturing and
Service settings.
What I can do for your organization.
2/11/2013 – v6.0
Over 5.8 million dollars of cost savings in LEAN and Six Sigma Projects through out career.
Trained led, coached and mentored over 75 Kaizens from 5S to Relayed Lines.
Delivered projects with over 50% of lead-time reductions on LEAN Events.
Improved On-time Delivery from 45% to 90% at Proserv Facility.
Delivered projects with over 30% of transportation reductions on Kaizen Events.
Led two companies to successful QS-9000 certifications.
Managed cross-functional teams to 17 successful Production Part Approval Process (PPAP).
Accomplishments
2/11/2013 – v6.0
Thank you for viewing my presentation
If you enjoyed the presentation or have questions, please contact me at [email protected] or call me at 832-486-0159. I am available to consult with your company or open to new opportunities.
Best regards,
Art Bolanos
2/11/2013 – v6.0