Imagination at work

Reduction of Hose Pipe Wastagein LV5 Assembly Line

April 19, 2016Pittsburgh, PA

Lean Manufacturing Project :

GE Energy Power Conversion

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Team

Kalpesh Patel identified the problem and brought it to notice and got the team together to work on this lean project. He lead the team to successfully complete this project.

Kalpesh Patel (Adv. Manufacturing

Engineer)

Akash M K (Manufacturing Specialist)

Akash helped in putting the data together and performed cost saving analysis and helped the team in implementing the solutions.

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Team

Rich Toal & Sean Shroyer have played a key role in this project. They have helped the team in collecting data and successful implementation of the solutions

Rich Toal & Sean Shroyer (Shift Leads)

Jason(Assembler Station5)Jason aided the team in

data collection by routing hose pipes till satisfactory results were obtained.

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ProblemSupply of lengthy hose pipes to the LV 5 assembly line to route them from the PE cabinets to the respective AC cabinets.

- The length of the hose pipes supplied is 21% excessive than the required length. - More time spent in handling, installing and cutting of the extra length of the hose pipe.WastageOn a average the wastage was 3.5 ft. long. The maximum recorded waste was 5ft

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Indicators of the Problem1. Garbage Bins 2. Interfering with

work

3. Damage the Board

4. Time Waste

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Data CollectionCurrent length being supplied

Wastage: 20.51 ft (246.12 in.)Hose Pipe

RoutingLeft (in)

Right(in)

PE 1 to AC 1 144 144PE 2 to AC 2 144 144PE 3 to AC 3 144 144PE 4 to AC 4 144 144

Hose Pipe Routing

Left (in)

Right (in)

PE 1 to AC 1 51 15.5PE 2 to AC 2 46.75 11.25PE 3 to AC 3 46 12.5PE 4 to AC 4 50 13.5

PE 1 to AC 1 PE 2 to AC 2 PE 3 to AC 3 PE 4 to AC 40

20

40

60

80

100

120

140

160144 144 144 144144 144 144 144

51 46.75 46 50

15.5 11.25 12.5 13.5

Current vs Waste

Current Left Current Right Waste (Left) Waste (Right)

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AnalysisInitial Length Supplied : 12ft. (i.e. 144 inches)Quantity : 8 Pcs.

AC to PE Cabinets Supplied Measure(inches)

Actual Measure(inches)

Waste(inches)

AC1 left to PE1 Manifold 144 93 51AC2 left to PE2 Manifold 144 98 46AC3 left to PE3 Manifold 144 98.5 45.5AC4 left to PE4 Manifold 144 94.5 49.5AC 1 right to PE 1 top of

H.E.144 124 20

AC 2 right to PE 2 top of H.E.

144 134 10

AC 3 right to PE 3 top of H.E.

144 132 12

AC 4 right to PE 4 top of H.E.

144 129 15

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Analysis

a. Total length of Hose Pipe used to make the connections : 95 ft.b. 1 Spool consumed per 3 drivesc. 174 spools consumed yearly

1. Current:

Hose pipe spool length : 300 ft.

2. Proposed Changes :a. Total length of Hose Pipe used to make the connections : 75 ft.b. 1 Spool consumed per 4 drivesc. 130 spools consumed yearly Hose Pipe Spool consumption reduced by 44 spools

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SolutionProvide proper cut lengths to Station 5 in a cart Actual Measure

(inches)93989894124134132129

AC to PE CabinetsAC1 left to PE1 ManifoldAC2 left to PE2 ManifoldAC3 left to PE3 ManifoldAC4 left to PE4 ManifoldAC 1 right to PE 1 top of

H.E.AC 2 right to PE 2 top of

H.E.AC 3 right to PE 3 top of

H.E.AC 4 right to PE 4 top of

H.E.In Negotiations to get the hose pipes pre cut from outside

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Savings

Costs SavingsTotal Savings $125,100

Material Cost $48,000A. Saved material $39,000B. Unused Material in Spool $9.000Spool savings (44 spools) $38,500Labor Cost $26,500A. Shipping $3,000B. Cutting & Supply $23,500Material Handling Cost (33% )

$9,000

Freight Cost (7%) $2,700Ordering Cost (1%) $400

1. Total Savings = $125, 1002. Reduces Ergo Risks by 33%3. Reduces Material Handling and Damages by 33%Approx.

$75,000

Overall Savings = $200K

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Implementation, Control & 5S:• Leads Rich Toal and Sean Shroyer will implement this under the

guidance of Manufacturing Engineer Kalpesh Patel. Also, convey the changes to the second shift.

• Proper 5S Practice will be utilized in the implementation of this project

• Shift Leads will get the 2nd shift trained on the proper routing practice

• Further changes in length should be reported to Kalpesh Patel and should be proceed only if approved. Also, the changes has to be notified to all the shifts leads

Phase 2:The team is currently working on the second phase of the project and will do the same exercise to determine the proper lengths for the plinth hose pipes. Based on this project the proposed savings for this phase will be around $300K

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