lean article. support slides
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Lean Article. Support Slides. Slide 1. What We Have Done: People Involved. Area Manager. Head of Logistics. Executive Management. Head of Operations. Plant Managers. Executive Management. Slide 2. Type and frequency of customer demand and demand flow. CS. X trucks per day - PowerPoint PPT PresentationTRANSCRIPT
Lean Article.Support Slides.
04/19/23 Fußzeile Slide 1
Slide 1. What We Have Done: People Involved
Area Manager Head of Logistics Executive Management
Head of Operations Plant Managers Executive Management
04/19/23 Fußzeile Slide 2
Slide 2. Type and frequency of customer demand and demand flow
Prep / Sort Customer and LifeGas Cylinders
Cylinders Filled
# of trucks arriving from customers
CustomerXX Cylinders
XX%
LifeGasXX Cylinders
XX%
CS
FS
PD
WE
O2 LIVXX Cylinders
XX%
Other GasesXX Cylinders
XX%
O2 LargeXX Cylinders
XX%
VGLsXX Cylinders
XX%
O2 Small Pin Index
XX CylindersXX%
X trucks per day
XX - XXX Cylinders
04/19/23 Fußzeile Slide 3
Slide 3. Current State:Step 3: Map the current value stream
Production Ticket Production Ticket
Delivery Ticket
CustomerDeliver from
Customer
Deliver toCustomer
IRange: 0 – 1400Avg.: 700
Loading8 FTEs
IRange: 0 – 1400Avg.: 700
Filling2.5 FTEs
IRange: 0 – 1400Avg.: 700
Prep2 FTEs
Office XXX
04/19/23 Fußzeile Slide 4
“Simplify” Create new plant flow and layout of facility
— Review the current state “spaghetti” diagram
— Assess where redundancy exists
— Eliminate excess distance traveled
— Reduce cross contamination of products where possible
— “poke-yoke” (mistake proof) where possible
— Standardize processes where possible
— Look for opportunities for visual management
22.04.2010 5
1
3
2
9
12
8
4
6
11
10
7
13
14
15
16
17
Cylinder Drop Off
Prep Area
Hydro
Bio-med - Dirty
Bio-med Clean
Technical Cabinet
Office Entry
Cylinder Staging
Full Cylinders
Full Other Gas Cyl
Cylinder Testing
VGL Filling
Large O2 Filling
Hydro Storage
Forklift
5 Filling
Medical excess
18 Nitrous Cage
19 Second Office
1S
3b2a
4
6S
5
9a
12
8a
11
10
7a
13
14a
15
16a
18
19
1 truck
1L
2b3a
7b
8b
8c
9b
9c8d
10
14b
15
16b
16c
17a
17b
17c
6L17d
Current State HoustonCurrent State Houston
75 ft 104 ft
108 ft
227 ft
120 ft105 ft
79 ft
196 ft
42 ft
53 ft
5 ft
135 ft
Empty
58 ft
88 ft
76 ft
108 ft
145 ft
Full
68 ft
21 ft
Retest
98 ft
72 ft
82 ft
88 ft
114 ft
79 ft
227 ft
201 ft
10 ft
10 ft
Slide 4. Current State Analysis and Future State Development
22.04.2010 18
1
3
2
9
12
8
4
6
11
10
7
13
14
15
16
17
Cylinder Drop Off
Prep Area
Hydro
Bio-med - Dirty
Bio-med Clean
Technical Cabinet
Office Entry
Cylinder Staging
Full Cylinders
Full Other Gas Cyl
Cylinder Testing
VGL Filling
Large O2 Filling
Hydro Storage
Forklift
5 Filling
Medical excess
18 Nitrous Cage
19 Second Office1 truck
Future State HoustonFuture State Houston
Full Full Spec Spec GasGas
HQAAHQAAHQAAHQAA
HQAAHQAA
HQAAHQAA
StageStage
Dri
ver
Lan
es
Dri
ver
Lan
es
Hyd
roH
yd
ro
Dri
ver
Dri
ver
Lan
es
Lan
es
Cu
st
Cu
st . .
Pic
kP
ick
Fu
ll M
H /
F
ull M
H /
Ass
et
Ass
et
Pre
pP
rep
Customer EmptyCustomer Empty
M / T / W / T / F / AssetM / T / W / T / F / Asset
AssetAsset
97 ft97 ft29 ft29 ft
16 ft16 ft
20 ft20 ft
20 ft20 ft
130 ft130 ft
5 ft5 ft
67 ft67 ft
45 ft45 ft
81 ft81 ft
130 ft130 ft
04/19/23 Fußzeile Slide 5
Sm
all
23
4 f
tSm
all
23
4 f
t
Larg
e 3
06
ft
Larg
e 3
06
ft
VG
L 2
27
ft
VG
L 2
27
ft
Texans
25% added to distance due to searching for cylinders since lack of order exists
25% added to distance due to searching for cylinders since lack of order exists
Slide 5. Measure Current Performance“Easy to Read Fashion”
Empty Small: 234Ft
Empty Large: 306Ft
Empty VGL: 227Ft
Full Small: 233FT
Full Large: 184FT
Full VGL: 227 FT
23
3ft
23
3ft
18
4ft
18
4ft
22
7ft
22
7ft
04/19/23 Fußzeile Slide 6
“5 Ys” 5Ys Overview
— Lincoln Memorial Story….
— Provide simple overview of why we will be asking so many questions of the employees
“Why 5S Is So Important” 5S Exercise
— Paper simulation searching for numbers while 5S is applied to the “workspace”
— Physically demonstrates to employees how 5S can reduce workload
— Sort / Set In Order / Shine / Standardize / Sustain
Slide 6. What We Have Done:Current State Assessment
Day 2 Day 3 Day 4 Day 5Day 1
04/19/23 Fußzeile Slide 7
Before
— Unorganized and lacking clear placement of product
— Excess inventory
— Management challenge
After
Slide 7. What We Have Accomplished:Before & After
04/19/23 Fußzeile Slide 8
Slide 8. Large Cylinder Storage
Before
— Lack of organization
After
— Color coded painting on floor for clear separation
— Installation of “visual” Kanban using floor coloring
04/19/23 Fußzeile Slide 9
Slide 9. What We Have Accomplished:Before & After
Before
— Drivers randomly dropping product where space is available
— Co-mingled Asset and Customer owned cylinders
After
— Create prioritization lanes for what to be filled next – visual management
— Separate Customer owned and Asset cylinders
— Add mural and signature board for commitment to the process