KaizenLean Manufacturing

September 23, 2015

Team membersScottLaura Facilitator: Jeff RDiane AHiaPinaVirginiaDavidYessicaDiana D

Team Picture

Kaizen event agenda Training • Introduction • - Kaizen Concepts & Process • SPACER• - Lean - Waste • - Process Flow Analysis • - Spaghetti Diagrams

• 2 teams• Walk the process STEPS• TIME it takes to complete

a part at each process

Lunch

• Floor Work

• - Process Flow Analysis • - Spaghetti Diagrams • Team Reports

Training • 5S• Total Quality• Pull Systems• Paper Air Plane• Batch Process• One piece flow

Lunch

Floor Work • Work in your areas

and evaluate how we can use 5S

• Team Reports

Training • Takt Time• Line Balancing• Cell Design Layout

• 2 teams• 5S work areas

• 3 teams• Prep• Solder• Term

Lunch

Floor Work • Layout the

workstations • Evaluate Agree on

the cell design• Team Reports

Training • “Implement”• Create Cell

• Move benches• Organize area

• Team evaluation• Re-organize if

necessary

• Prepare line for a production run on Friday morning

Training • TEST RUN

• Make any adjustments necessary

• Spaghetti and time the new process

• Team report out

Learn Lean

ObjectivesCreate a competitive advantage for ICSReduce lead timesImprove yieldReduce costImprove efficiencies and product throughputIntroduce workforce to Lean ConceptsCreate a cell producing with “one piece flow”

Project GoalsOpportunity to increase revenue

Goal OwnerFaster throughput 30% Jeff R

Decreased lead-time

Higher quality 30 % Jeff R / GemalynReduction in NCMR’s

Production capability 30% Jeff RParts produced to FG daily

Spaghetti

Team Spaghetti

Team Spaghetti Travel Waste = Motion & Transportation

Results:Pre: Post: Improvement:

Total Steps: 615 10 6050% Astronomical!!Distance Feet: 1845’ 30’ 1815’ Less TravelAmount of Time: 1 hr 15 sec 59min 45secTime SavingsComputer Trips: 12 2 88% Fewer Trips

5S

5SWhat is it?

Cleaner work areasMore organizationSafer working conditionsLess wasted timeEfficient work processes and practicesMore available space

Everything has a place and everything is in it’s place

5SExample

Guess who?

After:Before:

Same person?

Cell Layout

Cell DesignTeam focused on Pull over Batch processing

In line (in-process) inspectionEveryone inspects the quality of incoming product first

Studied “One Piece Flow” with a Paper Airplane Exercise.

Discussed cell layouts by process

Created a “U Shape” cell as a team

Cell Design

Cell TeamResults:

Pre: Post: Improvement:Throughput Time: 44min 2min 15sec MUCH FASTER !!Quality: Unknown In Line Inspect Built in QualityLabor Time: 89 hr act 30 hr 197% Time SavingsDistance Feet: 1845’ 30’ 1815’ Less TravelSpace / Foot print sqft 10,800’ 216’ 10,584 sqft Savings

Parts per hour: 2 26 1200% More per hour

Production Lead Time: 3 weeks 2 days Happy Customers!

Action Items

5S a shelving rack at the cell for necessary itemsAkro bins of different sizes (blue), set-up supplies, 5S place mats

Install a Tin pot bench in the cell Jeff/Scott due Nov 1Currently only 2 Tin pots available Jeff/Scott due Nov 1Table over-head lights Scott due Oct 1Only 2 stripping machines Curt evaluate future needSet-up (scrap) piece sent with WO kit JeffDetermine future cell product Jeff/Scott ongoingCurrent team members to train others in the cell All / anyNeed food…burritos if you watch Laura ongoing

Have fun !!