20627 Utica Finished Assemblies Tugger

Acuity Business SystemAcuity Business SystemAcuity Business SystemAcuity Business System

Material Handling Kaizen Report OutFinished Assembly Tugger Delivery

Utica

June 27, 2008


Finished Goods and Purchased Part Delivery Tugger System


Team

Doug Tegtmeier, Andy Scott (Team Leader), Lori Kinzer, Dwight Reynolds, Rob FowlerDoug Tegtmeier, Andy Scott (Team Leader), Lori Kinzer, Dwight Reynolds, Rob Fowler


Charter

Business Case:

TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $.82 The purpose of the event is to establish a Work Standard using a Tugger system to pick up and deliver needed materials to the Assembly cells and pick up and deliver Finished Assemblies to the shipping dock. Currently, There is a one forklift driver dedicated to picking up finished assemblies and taking them to the dock. The Tugger will now pickup and deliver finished assemblies on his regular route.

Business Case:

TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $.82 The purpose of the event is to establish a Work Standard using a Tugger system to pick up and deliver needed materials to the Assembly cells and pick up and deliver Finished Assemblies to the shipping dock. Currently, There is a one forklift driver dedicated to picking up finished assemblies and taking them to the dock. The Tugger will now pickup and deliver finished assemblies on his regular route.


Charter


Work Standard Elements

Work Elements

0.6 Seconds Each step the tugger operator takes (2.5 feet per step)

3.66 Feet per Seconds Tugger Travel Time estimated 2.5 miles per hour

3.9 Seconds Get on tugger

3.9 Seconds Get off tugger

7 Seconds per container Deliver container/ Pick up empty

37 Seconds Unhook empty/ Unhook empty from empty/ move empty to staging area/ re-hook other empty

17 Seconds Walk from stop/ to FG cart/ move FG cart to end of train and hook to train

28.1 Seconds Tugger remove (1) skid from stack and place on empty cart

22.3 Seconds Shipping unload time per (1) full cart


Standard Work Calculation

PART#STANDARD

PACKPIECES PER

UNIT Daily UsageDaily Total

Usage# of containers

per day# of containers

per hour

# of containers per hour * 7 secs

per container (pickup/delivery)

GA-1054 50 1 72 72 1.4 0.2 1.4

SC-2951 100 2 72 144 1.4 0.2 1.4

SC-989 100 2 72 144 1.4 0.2 1.4

SC-641 200 2 72 144 0.7 0.1 0.7

SC-2944 100 2 72 144 1.4 0.2 1.4

SC-456 1000 5 72 360 0.4 0.0 0.3

MI-3054 200 3 72 216 1.1 0.1 1.0

93.1+7.8+54 sec.Total=154.9 sec. (93.1sec. delivery and pick up of empty

bins + 7.8 sec. to get on and get off tugger + walk time around cell)Total=154.9 sec. (93.1sec. delivery and pick up of empty bins + 7.8 sec. to get on and get off tugger + walk time around cell)


Time Study


Number of Skids per Hour/Route.


1 Hour Coupled Route Parameters

Minimum Requirements for a

one hour route frequency

Time Study #1 Time Study #2 Time Study #3 Time Study #4

Time Study #5 4 Finished

Assembly carts

Max load time

33% of total time

20 min. (0.33 x 60 min.)

7 min. 55 sec. 6 min. 40 sec.

11 min. 26 sec.

13 min. 26 sec. 25 min.

Max travel time

33% of non load time

13 min. 12 sec. (.33 x 40 min.)

*If load time were less than 33% (20

min.), maxim

um travel time could

be greater

.3 min. 40

sec. 3 min. 40 sec. 3 min. 40 sec. 3 min. 40 sec. 4 min. 40 sec.

Total Stop Time 27 min.

11 min. 10 sec.

13 min. 52 min. 9 min. 6 sec. 7 min. 15 sec. 21 min. 48 sec.

Total Time 60 min.

22 min. 45 sec.

24 min. 12 sec. 24 min. 4 sec.

24 min. 21 sec.

51 min. 28 sec.*


Kaizen Title

Operator No. Problem Measures Taken Results

Remarks

Name

Kaizen Sheet

1.1. Forklift were being used to move final

assemblies to shipping

Forklift were being used to move final

assemblies to shipping

Tugger will now take final assemblies to

shipping dock.

Tugger will now take final assemblies to

shipping dock.

Reduction in forklift waste

Reduction in forklift waste


Kaizen Title

Before Kaizen After Kaizen


Remarks

Name

Kaizen Sheet

2.2.No Signs for

assembly cellsNo Signs for

assembly cellsAdded signs above each assembly lineAdded signs above each assembly line

Better visual controlsBetter visual controls


Kaizen Title



Remarks

Name

Kaizen Sheet

3.3.Hard to get

leads in fixed tubes

Hard to get leads in

fixed tubes

Unscrewed lead tubesUnscrewed lead tubes

Each part has two tubes and

tugger and take one to fill

Each part has two tubes and

tugger and take one to fill


Kaizen Title



Remarks

Name

Kaizen Sheet

4.4.

Skid stacks were stacked too high for tugger to

reach

Skid stacks were stacked too high for tugger to

reach

Lowered signsLowered signs Controls stack hieghtControls stack hieght


Kaizen Title



Remarks

Name

Kaizen Sheet

5.5.Used forklifts, walk behind

forklifts to move final assemblies (Safety

issues, inefficient material movement methods).

Used forklifts, walk behind forklifts to move final assemblies (Safety

issues, inefficient material movement methods).

Started using a tugger vehicle to supply

assembly with parts and take final

assemblies to shipping dock

Started using a tugger vehicle to supply

assembly with parts and take final

assemblies to shipping dock

Optimal material delivery method.Optimal material delivery method.


Improved Delivery Route


Report Card/Newspaper

Paint lines on floor for cart staging Label carts when arrive with cell indicator and

skid part numbers Job responsibility list


Report Card/Newspaper


Questions?

Documents

20627 Utica Finished Assemblies Tugger