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Set-Up Analysis (2)Machine #:Set-Up Observation Analysis SheetDate:Part & OP:Page:of:StepTimeBeforeCategory#Cum.TaskInt/ExtElement / Task DescriptionPESTObservationsTotalsP.) Prepare E.) Exchange S.) Setting Conditions T.) Trial Runs & Adjustments# of Steps Moved to External:# of Steps Reduced:# of Steps Eliminated:Time Moved to External:Time Reduced:Time Eliminated:

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Routing analysisRouting AnalysisName:Area:Date:Part NumberAnnual VolumeMachine AMachine BMachine CMachine DMachine EMachine FFamilyAAA2845123AAB210123AAC769123AAD45821345

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SpaghettiSPAGHETTI DIAGRAMDate PreparedProcess Name:or Revised:Model Number:Scope ofFrom:Department:Operations:Model Name:To:Operators:

&L&8Form SPS8 8/1/1998&R&6&F

Set-Up AnalysisMachine #:Set-Up Observation Analysis SheetDate:Part & OP:Page:of:StepTimeBeforeCategoryAmount of time moved to:After#Cum.TaskInt/ExtElement / Task DescriptionPESTExternalReducedEliminatedTimeTotalsP.) Prepare A.) Exchange S.) Setting Conditions T.) Trial Runs & Adjustments# of Steps Moved to External:# of Steps Reduced:# of Steps Eliminated:Time Moved to External:Time Reduced:Time Eliminated:

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Set-Up Analysis Instr.Machine # - 300 Ton PressDate: 7/28/98Part & OP - SetupClassBeforeAmount of timeEst.AfterStep #TimeBeforeCategory by ActivityMove toAfterCategory by ActivityCumulativeTaskInt/ExtElement / Task DescriptionPESTExternalReducedEliminatedTimePEST1:40:40IClean Bottom TrayX:40:0021:21:41IVibrate Parts Down StackerX:41X32:561:35IPress to Bottom & Remove ClampsX:051:30X44:361:40IRemove Stacker BoltsX1:40:0055:02:26IAdjust StackerX:26:0066:211:19IRemove Top StackerX:40:39X77:08:47IRaise RamX:47X813:115:03IRemove DieX1:004:03X914:111:00IMeasure ToolX1:00:00X1017:313:20IClamp ToolX1:002:20X1119:001:29IInstall Top StackerX:40:49X1223:254:25IInstall Bottom Stacker RodsX4:25:001324:08:43ISet Scrap Box & Set HTX:20:23X1431:317:23ILoad Coil7:231534:232:52IAdjust for Material ThicknessX2:52X1635:331:10IAdjust MaterialX1:10X1739:263:53IAdjust / Clearance CheckX3:53X39:2639:26Totals:003:458:1127:30# of Steps Moved to External0# of Steps Reduced6# of Steps Eliminated5Time Moved to External:00Time Reduced3:45Time Eliminated8:11Activity CategoriesP. Prepare - Try to move these item to externalE. Exchange - Try to reduce or eliminate these itemsS. Setting Conditions - Try to eliminate these itemsT. Trial Runs & Adjustments - Try to eliminate these items

&ABrief Task DescriptionRunning total time on stop watchIndividual component times.14:11 - 13:11 = 1:00I = Internal TimeE= External TimePlace an X in the appropate category box. See definitions below.Total set-up timeTotal set-up timeAfter Changes

Problem Record SheetProblem Record SheetDate: __________Improvement Project::____________________ Team #: ____________Completed By: __________________________Description of Problem:Description of steps taken:Results:Before ImprovementAfter ImprovementRemarks:

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RoadmapItemDescriptionLevel 1Level 2Level 3Level 4Level 51TAKT Time ProductionNo TAKT TimeTAKT time exists, but production regularly exceeds TAKT timeProduction is consistently below TAKT timeProduction consistently meets TAKT timeAll production is performed within TAKT time using one operator in the cell2Flow Line ProductionProduction separated by isolated job shopsSome FlowSeparate Flow LineOpen house flow lineOne stroke Flow line3Operator flexibilitySingle process, single skilled operators; sitting operationsMulti process skilled operators; standing operationsSupporting process skill Operators; walking operatorsSingle product processes operatorsMulti product processes operators4Production FlowProduct moves by the palletProduct moves by the box / trayProduct moves via on line chutesProduct moves in one piece flowProduct moves in one piece flow to end customer demand5Equipment FlexibilityBattle Ship & Cannon - Big Capacity hi speed machines unrelated to TAKT & Demand; Using huge machines for small products ,sophisticated computers/robots for simple products (overkill)Equipment is selected prior to understanding TAKT or doing line design. Then line is designed around equipmentEquipment suitable for line speedOne to one relationship between processes & machines - fixed speed (one process one machine)One process one machine variable speed6Production PlanningMonthly PlanningWeekly PlanningDaily Planning to demandHourly Planning to customer demandOne set planning to demand7Set Up TimeOver ten minutesSingle minuteZero minutes (