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Lean Pull System
Kaizen
Team 2Lean ManufacturingNovember 9, 2015
Team membersLorenaSylviaCathy CFacilitator: Jeff R.Claudia SRogerRhondaGemalynJoseMaria N
Team Picture
Kaizen event agenda Training Introduction - Kaizen Concepts & Process SPACER- Lean - Waste - Process Flow Analysis - Spaghetti Diagrams 2 teamsWalk the process STEPSTIME it takes to complete a part at each process
Lunch
Floor Work
- Process Flow Analysis - Spaghetti Diagrams Team Reports
Training 5STotal QualityPull SystemsPaper Air PlaneBatch ProcessOne piece flow
Lunch
Floor Work Work in your areas and evaluate how we can use 5S
Team Reports
Training Takt TimeLine BalancingCell Design Layout
5S TeamSet-upStaging
Quality TeamFirst pieceIn-process
Lunch
Floor Work Layout the workstations Evaluate Agree on the cell designTeam Reports
Training ImplementCreate CellMove benchesOrganize area
Team evaluationRe-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
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ObjectivesCreate a competitive advantage for ICSHeighten quality awareness within the cellsEstablish 1st piece build protocolsEstablish cell set-up / start-up protocols5S cell set-up and staging racksIntroduce workforce to Lean Concepts
objetivosCrear una ventaja competitiva para el ICSAumentar la conciencia de la calidad dentro de las clulasEstablecer protocolos pieza construccin 1Establecer / protocolos de puesta en marcha celular configurar-upCelular 5S configuracin y bastidores de estadificacinIntroducir fuerza de trabajo a Lean Conceptos
Project GoalsOpportunity to increase revenue GoalOwnerFaster throughput 30%Jeff RDecreased lead-time
Higher quality yields 30 %Jeff R / Gemalyn
Production capability 30% Jeff RParts produced to FG daily
Objetivos del proyectoOportunidad para aumentar los ingresosObjetivo propietarioRendimiento ms rpido 30% Jeff RDisminucin del tiempo de entrega
Rendimientos ms altos de calidad 30% Jeff R / Gemalyn
La capacidad de produccin 30% Jeff RPiezas producidas a FG diaria
Spaghetti
Team 2 Spaghetti
Team Spaghetti Travel Waste = Motion & Transportation
Results:
Pre:Cell: Improvement:Total Steps:857108470% Astronomical!!Distance Feet:2571302541 Less TravelAmount of Time:50 min15 sec49min 45secTime SavingsComputer Trips: 12288% Fewer Trips
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Equipo SpaghettiViajarResiduos = Movimiento y Transporte
Resultados:
Pre: Celda: Mejora:Pasos totales: 857/ 10 8470% Astronmica !!Pies Distancia: 2571/ 30' 2541Menos ViajesCantidad de tiempo: 50 min / 15 seg Ahorros 49minViajes informticos: 12/ 2 88% menos viajes
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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 its place
SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN
5SQu es?Las reas de trabajo ms limpiasMs organizacinLas condiciones de trabajo ms segurasMenos tiempo perdidoProcesos y prcticas de trabajo eficientesMs espacio disponible
Todo tiene un lugar y todo est en su lugar
SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN
SORT, poner en orden, BRILLO, estandarizar, SUSTAIN
5SExample: Cell Set-up Shelves
After:
Before:
Teamwork Cell Start-up
Focused cell set-upCelular enfocada puesta a punto
More efficientMs eficiente
Clear instructionsInstrucciones claras
Checklist
QualityFirst Piece Verification
Calidad Primera Verificacin pieza
Focused on quality Form travels along with the first part during the build
Quality of the line is signed off before cell can proceed with production
Checklist
Centrado en la calidadForma transportar a lo largo con la primera parte durante la construccin
Calidad de la lnea se firm antes de celular puede proceder con la produccin
Lista de verificacin
First Piece Verification
Quality / Inspection must sign off completion
Triggers the start of production
Form will live in the cell during production
Cell DesignTeam focused on Pull over Batch processing
Studied One Piece Flow with a Paper Airplane Exercise.
Learned cell layouts and effectiveness
Created a U Shape cell as a team
Diseo de la clulaEquipo se centr en Tire sobre el procesamiento por lotes
Estudi "One Piece Flow" con un aeroplano de papel Ejercicio.
Diseos celulares aprendidas y eficacia
Creado una clula "U" en equipo
Cell Design
Cell Team Results:
Pre:Post: Improvement:Total Cycle Time:30min 12min MUCH FASTER !!FG Completed Takt:30min4min650% Improvement!!Quality:UnknownIn Line InspectBuilt in QualityLabor Time:96.9 hr act77.2 hr25% Labor SavingsDistance Feet:1845301815 Less TravelSpace / Foot print ft214400ft2216ft214,184 ft2 SavingsParts per hour: 215650% More per hourProduction Lead Time:3 weeks2 daysHappy Customers!
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Have Fun !!
The journey has just begun
to be continuedContinuously!
El viaje acaba de comenzar
continuarContinuamente!
Integrated Cable Systems
Cell Set-up / Start-up Protocol
CHECKLIST
|_|CLOCK IN / WORK ORDER
All operators / technicians must Clock on to appropriate process sequence
|_|VERIFY BUILD SHEETS: Rev level to Work Order Stations have copies posted
|_|TOOLING: All tooling is available and verified Dispersed to stations
|_|PARTS / COMPONENTS: Verify parts to the build sheets Collect any required pre-cut tubing
|_|LABELS: Distribute labels
|_|PROCESS STATIONS: Identify and tape WIP locations in the line Set-up all stations for production then every operator / technician must Verify incoming process for in-line inspection on every part
|_|NOTIFY QUALITY: Inform quality / inspection of cell start-up
|_|FIRST PIECE VERIFICATION: First process station operator / technician is responsible to: Initiate & Fill out top of form including Work Order ID / Assembly ID / Rev Level / Date Form will flow though the line with the first assembly part
ICS Form XXX - XXXX
Date: _________________________Integrated Cable SystemsAssembly Build Verification
First Piece VerificationWork Order IDAssembly IDRev Level
CHECKLIST Employee # InitIals
|_|PREP: Process complete per ICS build sheet Employee # Initials
|_|TERM: Crimp height measurement: ___________ Process complete per ICS build sheet Hand Tool # or Applicator #: ___________ Employee # Initials
|_|PLUG: Process complete per ICS build sheet Employee # Initials
|_|TIN: Process complete per ICS build sheet Employee # Initials
|_|SOLDER: Process complete per ICS build sheet Employee # Initials
|_|LABEL: Paste 1x ea below of every label on assembly. Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.
Attention: Paste on back of form if necessaryEmployee # Initials
|_|CLOSE: Process complete per ICS build sheet Employee # Initials
|_|TYWRAP: Process complete per ICS build sheet Employee # Initials
|_|COIL: Process complete per ICS build sheetEmployee # Initials
|_|WINDING: Process complete per ICS build sheet Employee # Initials
|_|___________________: Process complete per ICS build sheet Employee # Initials
|_|TEST: Process complete / Electronic Signature: ______________________________ Inspector # Initials
|_|FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per: customer print / specification / ICS build sheet Approved for continued manufacture Inspector # Initials
ICS Form XXX - XXXX
Date: _________________________Integrated Cable SystemsAssembly Build Verification
First Piece VerificationWork Order IDAssembly IDRev Level
CHECKLIST Employee # InitIals
|_|PREP: Process complete per ICS build sheet Employee # Initials
|_|TERM: Crimp height measurement: ___________ Process complete per ICS build sheet Hand Tool # or Applicator #: ___________ Employee # Initials
|_|PLUG: Process complete per ICS build sheet Employee # Initials
|_|TIN: Process complete per ICS build sheet Employee # Initials
|_|SOLDER: Process complete per ICS build sheet Employee # Initials
|_|LABEL: Paste 1x ea below of every label on assembly. Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.
Attention: Paste on back of form if necessaryEmployee # Initials
|_|CLOSE: Process complete per ICS build sheet Employee # Initials
|_|TYWRAP: Process complete per ICS build sheet Employee # Initials
|_|COIL: Process complete per ICS build sheetEmployee # Initials
|_|WINDING: Process complete per ICS build sheet Employee # Initials
|_|___________________: Process complete per ICS build sheet Employee # Initials
|_|TEST: Process complete / Electronic Signature: ______________________________ Inspector # Initials
|_|FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per: customer print / specification / ICS build sheet Approved for continued manufacture Inspector # Initials
ICS Form XXX - XXXX