the trading cards 09-11-14 final t - review 09-11-14

ve

The Trading Cards

Andrew

Tim

Dave

Brian

Kevin

Member

The Trading Cards

Coach

The Trading Cards

Co-Chair

Dave 3 YrsScore129

The Trading Cards

Secretary

Brian 1.1 yrsScore135

The Trading Cards

Member

Kevin 1.5Score190

The Trading Cards

Andrew 3 Yrs Score135

The Trading Cards

Coach

Ron 16 YrsTSS Cord.

Robin 16 YrsAssistant Mgr.

The Trading Cards

Chairperson

Tim 16 YrsScore 194

Facility built 1989

300+ Associates

We are in Barrie Ontario

The distance between Matsu and Honda is 37 km or 30 minutes ; Toyota is 192 KM or 2 hours and 37 minutes.

MAP2D / 4D Accord

RDX

TL

CIVIC MDX

ZDX

CR-V

CIVIC HMIN

TOYOTA

RAV4

ELP

YMA

MAP

HCM 2HCM 1

Body PartsWeld 136 ROBOTS

SFT Weld SFT Paint SFT Assembly Final Inspection

Our Team’s Department

SFT

1

The baseball

represents the current

step

Team Members Communication Organization

Circle Knowledge

Trouble shooting

Computer experience Score

Tim R 5 5 5 5 5 25Kevin K 5 5 1 4 4 19Dave S 5 3 1 3 3 15Brian M 4 3 1 3 4 15Andrew T 3 3 1 3 3 12

Team DevelopmentOfficer Selection Chart

1

Strengths

Improvement Areas

TIM R DAVE S BRIAN M KEVIN KANDREW T

PersistentCompetitive

Determined Likes authority

Learn multi-tasking Listening

LoyalGood listener

PeacemakerAdaptable

Finishing tasks Self-worth

Good communicatorCreative Visionary

Attention to detail.

1

Team Development

Trent Smalley Personality test

Meetings every Wed morning at 7:30 amMembers must attend 75% of meetingsAt least 3 team members per meetingMust sign attendance sheetStay focused during meetingsOne person gets the floor at all timesDecisions are made final by the majority of the teamPoints system will be used to determine who gets to go when we wina. 1 point for attendance on timeb. 1 point for participation c. 1 point for assignments done on timed. The members with the highest points go on the tripChairperson sets up meetings & sets up assignmentsCo-Chairperson keeps order during meetingsSecretary keeps meeting minutes and goes over last meeting.

1

Code of Conduct

Team Development

STEP 1 - TEAM DEVELOPMENT

CIRCLE MEETING MINUTES FORM CIRCLE NAME _________________________________________

DEPT.:____________________________________ TODAY'S DATE___________________________ MEMBER'S ATTENDANCE

RESP. NAME (please print) CHECK FOR ATTENDING

LEADER

SUB-LEADER

SECRETARY

MEMBER

MEMBER

MEMBER

MEMBER

MENTOR

TODAY'S AGENDA

DESCRIPTION OF ACTIVITY (Please include names and titles of anyone attending that is not part

of your circle):

NEXT MEETING AGENDA:

OFFICER SELECTION CHART

Team Members Score Role

GRADING SCALE: 5 - High Skill 4 - Good Skill 3 - Average Skill 2 - Low Skill

COMMUNICATION COMPUTER EXP ORGANIZATION CIRCLE EXP LEADERSHIP

STEP 3 - ACTIVITY PLANACTIVITY PLAN

PLAN vs ACTUAL

QUALITY CIRCLE PROCESS STEPS

1) DEVELOP THE TEAM 2) REASON FOR THEME SELECTION 3) ACTIVITY PLAN 4) DATA COLLECTION FOR CURRENT SITUATION 5) ROOT CAUSE ANALYSIS 6) ROOT CAUSE IDENTIFICATION 7) ROOT CAUSE GOAL SETTING 8) COUNTERMEASURE SELECTION & PRIORITIZATION 9) COUNTERMEASURE PLANNING (PLAN) 10) COUNTERMEASURE TESTING (D0) 11 COUNTERMEASURE VERIFICATION (CHECK) 12) COUNTERMEASURE STANDARDIZATION (ACT) 13) DATA COMPARISON SUMMARY 14) GOAL PLAN vs. ACTUAL 15) ACTUAL PLAN 16) IMPACT ANALYSIS

PLAN

1

Team Development

Reduce Waste

Reduce Water usage

Reuse Rinse Water

Reduce Impact to the

Environment

ReuseMasking

ReducePlastic Waste

ReducePaper Waste

ReduceMachine

Downtime

Theme SelectionBrain Storming

2

Theme Selection Matrix

2

THEME IDEA If situation is improved BENEFIT

If nothing is done NEGATIVE IMPACT ACHIEVABILITY TOTAL

ASSOCIATES BUSINESS ASSOCIATES BUSINESS

Reduce water usage 3 5 3 5 5 21

Reduce Paper 3 4 3 4 2 16

Reuse Masking's 3 4 3 3 3 16

Reduce waste 3 5 3 5 5 21

We would like to re-circulate the rinse waters from rinse 1 back into system through an ICG unit(similar to the ones we have for pre-treat and the hot water rinse). ICG Unit

ICG unit

2

Theme Selection

Clayton RAssistant Manager SFT

Chris MSFT Coordinator

Glenn BSFT Coordinator

2

280

.10%

5%

Theme Selection – Link to Business Plan

Internal Stakeholders

ManagersCoordinators

Team Leaders Associates

2

External Stakeholders

Customer's

Toyota RAV 4

Honda

City Of Barrie

Environment

Potential New Business

2

SET STANDARD LEVEL

PROJECT

PROBLEM

POTENTIAL ACHIEVEMENT LEVEL

BELOW STANDARD ACHIEVEMENT LEVEL

51.1 Liters Per Minute (current situation)

A planned reduction of water used by 5% (10.22 ) Liters per minute

2

Using our company’s Business Plan a reduction of 5%is our potential achievement level

Project Statement Action : Reduce

Object: Rinse water

Why: to reduce water costs

When: June 1, 2014

What Cost : Less than $ 10,000.00

3

QUALITY CIRCLE PROCESS STEPS JAN FEB MAR APR MAY JUN JUL AUG SEP

1) DEVELOP THE TEAM PLANACTUAL

2) REASON FOR THEME SELECTION PLANACTUAL

3) PROJ ECT STATEMENT PLANACTUAL

4) ACTIVITY PLAN PLANACTUAL

5) SITUATION DESCRIPTION PLANACTUAL

6) SITUATION ANALYSIS PLANACTUAL

7) GOALS AND POTENTIAL BENEFITS PLANACTUAL

8) OBJ ECTIVE DEVELOPMENT PLANACTUAL

9) DEVELOP IMPROVEMENT ALTERNATIVES PLANACTUAL

10) DECISION ANALYSIS PLANACTUAL

11) PDCA - PLAN PLANACTUAL

12) PDCA - DO PLANACTUAL

13) PDCA - CHECK PLANACTUAL

14) PDCA - ACT PLANACTUAL

15) COMPARISON SUMMARY PLANACTUAL

16) ACTIVITY PLAN (PLANNED VS ACTUAL) PLANACTUAL

PLAN

Activity Plan

4

Summer Shutdown Scheduled

5

Situation Description

Pre –Rinse (hot water)

Degreasing Tank

Rinse TankStage 1

Rinse Tank Stage 2

Rinse TankStage 3

Water Flow

Waste Stream

City Water

City Water

Closed loop system


5

Water flowcontrolled by this tap

Water meter recordswater usage

Out to a drain pipe

Pre-rinse 4 risers

Degreasing Tank – 12 risers

Rinse 14 risers

Rinse 25 risers

5


The water then gets dumped into the sewer system

Water then gets stored in the twotanks

Rinse # 1

Rinse # 2

Rinse # 3

As these two tanks get full they dump the waste water

Rinse # 2 Rinse # 1

Water overflow

51.1 Liters of water in per minute

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar0

500

1000

1500

2000

2500

3000

3500

Water Usage 2013 vs 2014

Cubic Metres

of Water

5


Metric conversion:

1 Gallon = 3.78 Liters

5

FINAL RINSE MAKE-UP VOLUMEDATE TIME METER READING CHANGE RUN TIME (mins) FLOW RATE CHECKED BY01-Feb 0:30 123990 0 1080 12.5 RS02-Feb 0:30 135640 11650 1080 12.5 RS03-Feb 0:30 147300 11660 1080 12.5 RS04-Feb 0:00 158360 11060 1050 12.5 RS05-Feb06-Feb07-Feb 12:30AM 169850 11490 1080 12.5 RS08-Feb 12:30AM 181410 11560 1080 12.5 RS09-Feb 12:30AM 193000 11590 1080 12.5 RS10-Feb 12:30AM 204530 11530 1080 12.5 RS11-Feb 12:00AM 215800 11270 1050 12.5 RS12-Feb 4:30PM 221430 5630 510 12.5 RS13-Feb14-Feb 12:30AM 232900 11470 1080 12.5 RS15-Feb 12:30AM 244320 11420 1080 12.5 RS16-Feb 12:30AM 255850 11530 1080 12.5 RS17-Feb 12:30AM 267390 11540 1080 12.5 RS18-Feb 12:00AM 279030 11640 1050 12.5 RS19-Feb 3:00PM 284780 5750 510 12.5 RS20-Feb21-Feb22-Feb 12:30AM 293850 9070 1080 12.5 RS23-Feb 12:30AM 307070 13220 1080 12.5 RS24-Feb 12:30AM 316250 9180 1080 12.5 RS25-Feb 12:00AM 329540 13290 1050 12.5 RS26-Feb 4:30PM 335260 5720 510 12.5 RS27-Feb28-Feb 12:30AM 340220 4960 1080 12.5 RS

216230

216230.0000 GALLONS818519.6368 LITRESTOTALS

5

Data for Situation Description

818519Liters used in February

At a cost of $ 2799.27

5

Current Situation Description

At a cost of

$3296.33

963841Liters used in March


5

High water flow into the system51.1 Liters per minute 3066 Liters per hour73,584 Liters per day73.59 M3 at a cost of $3.52 per M3 = $259.04On a daily Basis

High flow out into the drain / sewer 51.1 Liters per Minute3066 Liters per Hour73,584 Liters per day

5



To summarize:Over the two months of February and March, the fuel tank line used 1,782,360 litres of water

The cost for water for the fuel tank line for these 2 months was $6193.55

5

IDEAL IMAGE

6

The fuel tanks are rinsed thoroughly and the amount of water required to do

the rinsing is reduced to meet thecompany business plan reduction of 5%.There are no quality or customer issues.

Goal Setting

Reduce water flow in by 5 %

Reduction of water flow out will also be the same

Reduce by240,960.4

Liters

963,841.60 Liters

Down to 722,881.20 Liters

6

Using data from March 2014

Savings of $ 824.08

Per Month

Before after 25% Liters0

10

20

30

40

50

60

March

March

A Reduction

Of 5% would be 2.5 Liters

per Minute

New water flow would be 48.5 Liters per

minute

6

Goal Setting

Liters

Old water flowwas 51 Litersper minute

Goal Setting

SPECIFIC – Reduce water flow by 5%.

MEASURABLE – Used flow meter and recorded data on Check Sheet.

ATTAINABLE – With new water meter and daily checks.

RELEVANT – Set standard water flow that saves money.

TRACKABLE – Using Operation Standard and Check Sheet.

6

7

OBJECTIVES MUST WANT

MANDATORY MEASURABLE REALISTIC

Reduce water use

Have a set water Flow

Recycle water usage

Maintain current production

Low cost to implement

No additional manpower

No effect to quality

reduce water flow

Objective Development

8

Develop Improvement AlternativesIdea:

This ICG unit will have to be a bigger system than the ones we currently have; but this regeneration idea will reduce the amount of water we are using and reduce the amount we are wasting.

ICG unit

9

Decision Analysis

This ICG unit will have to be a bigger system than the ones we currently have; but this regeneration idea will reduce the amount of water we are using and reduce the amount we are wasting.

Plan to look at Recycle unit failed because of several factors1. Cost of the unit was too expensive2. Testing time would have taken too long3. Toyota approval needed

It was back to the drawing board!

Decision Analysis

9

Existing meter was not working correctly.

Decision Analysis

9

PlanSchedule install of new meterDevelop check sheet to assure

accuracy of new meter.

DoInstall the new meter

Make the check sheet.

CheckMonitor new meter

Check readings daily.

ActReview other water metersfor possible replacement (oldequipment) with TSS Mgr.

10

PDCA for Meter Replacement

Task Breakdown Tree Diagram and Resource EstimateMaterials Cost - $

Man Hours

500.00 2 hours

12.00 1 hour

.00 1 hour

0.00 1 hour

TOTAL IMPLEMENTATION COST : 512.00 5 hours

Order MeterReplace meter

daily recordings

make check sheet

review other water meters

Replace meter

Tss group

Tim R made the sheet

Dave checked daily , recorded

Tss group

Kevin

10

PDCA

Plan March April May June July Aug Plan

New Meter Install

Develop Check sheet

Monitor Meter

Review Other Meters

10

Plan

Schedule used

New meter installed April 30, 2014for more accurate readings.

Do

11Check sheet made from April on for 2014

Check

12

Data Verification by team member

Act

13

Potential areas for meter install

But wait!* Water tap accessible to anyone - therefore no control of water flow. * No Operation Standard specifying water flow rate.

***Water flow rate at 51 liters per minute!!!!!***

9

Decision Analysis

PlanSchedule install of lock

Develop operation standard to assure everyone understands use.

DoInstall the lock

Make the operation standard.

CheckMonitor the lock

Review with stakeholders

ActReview other taps that areAccessible by anyone with TSS Mgr.

10

PDCA for Tap lock and control

Order lock & keyInstall lock

make sure stakeholder's aware of lock use

Install lockMake operation standard

Review other taps in the plant

Tap Control

Tim R

Tim R made the sheet

Tim R

Tss group

Kevin

10

Plan

Plan March April May June July Aug

Order lock and key Plan

Make operation standard

Review with stakeholders

Complete testing to ensure no quality issues

Review other taps in the plant for replacement

Plan

10

Lock installed on water tapOnly leadership group has key

Laminated alert for stakeholderknowledge of what the lock is for and why it is in place

12

Do

Turn down water flow by adjusting tap

Step1 Step2

Step3

DYNE TESTING

13

Check

CUT CHECKS

Check

13

PH TESTING Check

13

With the tap controlled we did extra testing to ensure no quality issue outflow to the customer.

As we adjusted the water flow we found that it had no effect on paint quality.

13

Check

13

All check results within required

standards

ActPH TESTING

CUT CHECKS

DYNE TESTING

But wait!During a random check we foundthat the water pressure was set at 15psi.

9

Decision Analysis

We checked the operation standard and found that the setting was to be set at the standard range of between 9 and 15 psi!

P.M. Schedule

PlanLowering of PSI level

DoReduce PSI to set standard to

low end of the scale and test for performance

CheckCheck tanks for cleanliness

Perform Dyne

ActChange the standard to 9 PSIShare information with stakeholders

10

PDCA for PSI REDUCTION

11

Plan

Plan March April May June July Aug

Reduce PSI and Check Plan

Set standard

Review with stakeholder's

Review with TSS on other Gauges

DYNE TESTING

13

Check

Another DYNE check done

Data Comparison Summary

Savings of$3105.27

in one month

Reduce the water usage

14

95% reduction

14


Liters

Before change Planed Goal Actual Result 0

10

20

30

40

50

60

14Liters

51LitersPermin

48.5LitersPermin

15 LitersPermin

Planned Goal vs Actual Result


Wow!

Water Line before change

14


Water Line after change

Wastewater trench water level greatly reduced


















PLAN ACTUAL

ACTIVITY PLAN

15

Activity Schedule – Planned vs Actual

Revised work

schedule

Vacation and

Personal

Fuel tank shutdown

Feb water totals March Water Totals April Water Totals May Water Totals June water totals0

200000

400000

600000

800000

1000000

1200000

Liters Used

Liters Used

May water usage was

30,469 litres

June water usage was

25,396 litres

Environment - Less water being treated/less water being used Cost of water decreased

Water usage and waste decreasedAssociate awareness increased

16

APRTHE “DO” MONTH

LegendLiters used per month

May water usage was

30,469 litres

March water

usage was 963,841

litres

February water

usage was 818,519

litres

What was the benefit to our Department ?

Environment Impact

Associate awareness of water waste

Wastewater treatment plant

Power StationsLocal water systems

Predicted water cost savings of $ 37, 263.24 per year.

16

Project benefit

Wow!

COST TO IMPLEMENT

$ 200 for meter $ 300 for labour$ 12 for lock$ 30 for miscellaneous $ 542 Total cost

16

SAVINGS FROM REDUCED WATER USAGE

$3105.27/month OR $155.26/day (based on 20 day working month.

R.O.I. =

Divi

ded

by

R.O.I. = 3.5 days

STAKEHOLDER INVOLVEMENT

16

Project benefit

Henry P Brian LRichard S

Garry D Melissa TMattP

Project benefit

16

STAKEHOLDER INVOLVEMENT

Bruce NPlant Manager

Clayton RAssistant Sft

ManagerChris Mc

Sft Coordinator

Robin MAssistant New model

Manager / Coach

Kevin MTSS Manger Ron R

TSS Coordinator /Coach

Impact on StakeholdersImpact Matsu Customer Environment City of Barrie

Positive Save moneyPride in workEducating Associates

Attention to detail re: paint adhesion

Reduction of water treatment

Efficient industryMore available water in summer crisis

Negative Financial investment Aversion to change

Possible contamination

Reduced revenue

1

Project benefit

Department Pre-treat ImpactAwareness Operation StandardAccurate Water measurementFixed water meter

Plant wide ImpactCost of water usage to-dateshowed a reduction of over$ 12,421.08 dollars for 4 months.

16Before change Planed Goal Actual Result

0

10

20

30

40

50

60

51LitersPermin

48.5LitersPermin

15 LitersPermin

Liters

Project Benefit ( Impact Analysis )

Tim Improvement:

More understanding of Pre-treatImprovement of criticism Leadership Skills

Better understandingCost of water

David Improvement:

More aware of Pre-treatHow much we spend on waterMore InvolvementWhat did I Learn How pre-treat workedWhat is NYC Cost of water

16


Kevin Improvement :

Dyne testsMore of understanding of pre-treatUnderstanding of qualityWhat it takes to do PowerPointWhat did I LearnCost of water

16


Brian Improvement:

More aware of pre-treatMore aware of quality More aware of Ph testMore aware of Nitrate TestMore of Reuse/ Reduce/ Recycle.Better understanding of cost

Andrew Improvement:

More of how the fuel tank lineInvolvement in Quality Helping with people skillsWorking with PowerPoint Cost of the water

16


Tools used

17


















PLAN

Bar graph

Task tree

Smart ChartGantt Chart

Objective Development Chart

Team Members Communication Organization

Circle Knowledge

Trouble shooting

Computer experience Score

Tim R 5 5 5 5 5 25Kevin K 5 5 1 4 4 19Dave S 5 3 1 3 3 15Brian M 4 3 1 3 4 15Andrew T 3 3 1 3 3 12

Team Development Chart

17

Duties Shared Tim lead the team:Showed the team how to do anNYC Presentation.Developed the Presentation.

David did water meter readings.Had a say in the developmentof the Presentation .Did all assigned tasks on time

Brian did the minutes of the meetings.Did nitrate readings.Had a say in the development of the Presentation.Did all assigned tasks on time.

Andrew did the cut checks.Had a say in the Development of thePresentation.Did all assigned taskson time.

Kevin did the Dyne test.Researched the new meter. Had a say in the Presentation.Did all assigned tasks on time.

Thanks for your time

Tim

Dave

Brian

Andrew

Kevin

the trading cards 09-11-14 final t - review 09-11-14

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