TD Frame CNC - Cycle Time Reduction Kaizen

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Presentation Outline

• Company Background• Kaizen Location• Problem Selection• Team Composition• Objectives and Approach• Current Conditions• Cause Investigation• Counter Measures• Results• Follow-up Plan• Lessons Learned• Questions

Company Background

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• Privately held company, headquartered in Steinbach, MB

• Canada’s largest wood window and door manufacturer

• Supplier to Canada, United States, and some international markets

• One of southeastern Manitoba’s largest employers and have been since the 1960s (celebrating 115 years)

• Manufacturing performed in one facility (600,000 sq ft)

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Kaizen Location

• Frame CNC within the Terrace Door Business Unit

• 2 shift environment (days & evenings)

• One-piece flow process design

• 12 frames/shift output

• Highly custom product: varying by size,

operation, finish, & product type

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Problem Selection

Focus: Reduce cycle time at Frame CNC

Rationale: This is currently the longest cycle time throughout TD Fab (bottleneck)

Expected Benefit: Reduce Frame CNC cycle time by 20%

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10

15

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Picking

Planer

Stage 1 Glue

Stage 2 Glue(Streyfield)

Sash Moulding (2 panels)

Frame M

oulding

Final Cut Length

Wood Dipping/Dry

Prime &

Dry

Metal Cutting (FD2)

Frame CN

C & M

etal App

Panel CNC &

Metal App

Actual Cycle Time vs Takt(TD Fab)

Actual Time

TAKT

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Team Composition

Kaizen Team• Tiffany (Leader)• Gurjit (Manufacturing Technologist)• Peter (Machine Design Technologist)• Tuan (Day Shift Operator)• Tyler (Evening Shift Operator)• Nick ( Loewen Outside Eyes)• Mirjam (Loewen Outside Eyes)• Neil (Waber Mfg. Outside Eyes)• Heinji (Waber Mfg. Outside Eyes)• Jaden (Waber Mfg. Outside Eyes)

Team Support• Grant (Mfg. Manager)• Ken (Mfg. Eng. Manager)• Stephanie (CME Facilitator)

Objectives & Approach

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3 Day Kaizen• Training• Observations• Timings• Spaghetti Diagrams• Value Stream Map• Root Cause Analysis• Brainstorm Solutions• Value Graph• Implement Solutions• Reflection & Next Steps

Current Conditions

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Observations• Multiple processes combined on CNC machine • Parallel metal application work while CNC is running• Excessive motion within cell

TOTAL CYCLE TIME 31.5 min

Total Operator Time 31.5 minValue Added 35%Non-Value Added 15%Business Value Added 50%

Total Machine Time 16.0 minValue Added 81%Non-Value Added 13%Business Value Added 6%

Cause Investigation

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Root Cause• Multiple processes combined on CNC machine• Programming is not optimized (ex: tool speed)• Excessive clean up during metal application

Counter Measures

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Counter Measure - Motion

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Cause Effect Counter Measure

Before1,928 Feet

After524 Feet

• Unnecessary motion• Unnecessary travel• Bottlenecks

• Tools at point of use• Parts are located closer• Combined multiple

processes at station

• Station layout

73%Reduction

Counter Measure – Metal Application

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Cause Effect Counter Measure

• Extra processing• Longer cycle time• Bottleneck

• Removed excessive cleaning

• Removed spray adhesive process

• Relocated astragal app

• Parallel metal application work pulled operator from CNC

BEFORE AFTERTESTING

2 STEPS 1 STEP

Counter Measure - Programming

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Cause Effect Counter Measure

Before16.0 mins

After11.0 mins

• Long cycle time• Bottleneck• Excessive motion• Excessive tool changes

• Reduced tool changes• Reduced motion• Increased speed of CNC

• Programs not optimized (tool changes/speed)

• Combined multiple processes on CNC

30%Machine Cycle

Time Reduction

Results

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BEFORETOTAL CYCLE TIME 31.5 minOperator Time 31.5 minsMachine Time 16.0 mins

AFTERTOTAL CYCLE TIME 17.5 minOperator Time 17.5 minsMachine Time 11.0 mins

45%Cycle Time Reduction

(Original Goal 20%)

Follow-up Plan

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• Weekly Meetings (in process)• Before and After Videos (in process)• Testing & Timings (in process)• Cost Saving Analysis (in process)

29/37 Tasks Complete

78% Complete

Next Steps

Lessons LearnedTiffany: Asking the right questions can help accomplish tasks with big impact quickly.

Nick: Having key stakeholders helps break down the barriers to change.

Gurjit: Putting the right skill with the right job makes everything easier.

Peter: Ask why until you hit the root cause.

Tuan: All the activities I do everyday have opportunities for improvement.

Mirjam: Some solutions that can be done quickly can have a big effect.

Tyler: There are hidden tasks in every process where outside eyes can help expose them.

Heinji: It’s worth it to take the time to slow down for a day or two, to step back and evaluate.

Jaden: Little changes can add up to big changes.