1. IXL Group Productivity Improvement Project Presented by:
Danish Khan Project sponsor: Bernard Brussow Project Leader: Glenn
Meier Date: 23/03/2015
2. Three Key Performance Issues Emptying of scrap bins Coil
change Stillages Availability
3. Scrap Bins Before After
4. Cost Justification For Scrap Bins Previous average time 14
minutes Current average time 3 minutes Total time saved 11 minutes
Scrape bin empties/day 3 Time saved per press / day 33 0.55 of an
hour Press overhead rate $130 Dollars Total savings per press/day
$71.50 Dollars Total number of presses 7 Total saving per day
$500.50 Dollars Total savings per month $10,010.00 Dollars Scrap
Bin
5. Time Saved ! 14 3 11 33 0 5 10 15 20 25 30 35 Av. Before Av.
After Time saved/press Time saved per press /day Time (Minutes)
Time
6. Cost 71.5 500.5 10,010 $0.00 $2,000.00 $4,000.00 $6,000.00
$8,000.00 $10,000.00 $12,000.00 cost per press cost per day cost
per month Dollars Dollars
7. Coil Change PressShop Foundry Logistics Backshed Coils TF2
1.5 Minutes Research and development Assembly Backyard Stillages
Coils Relocation Map Stillages Coils
8. Coil change Time (Minutes) Before After
9. Cost Justification Previous average time 24 Minutes Current
average time 12.9 Minutes Total time saved 11.1 Minutes No of time
coil changes on a press 2 Time saved per press / day 22.2 0.37 of
an hour Press overhead rate $130 dollars Total cost per press/day
$48.10 dollars Total number of presses 7 Total cost per day $336.70
dollars Total cost per month $6,734.00 dollars Coil change
10. Cost Justification 24 12.9 11.1 22.2 0 5 10 15 20 25 30 Av.
Before Av. After Time saved/press Time saved per press /day Time
(minutes) Minutes
11. Cost Justification $48.00 $336.00 $6,734.00 $0.00 $1,000.00
$2,000.00 $3,000.00 $4,000.00 $5,000.00 $6,000.00 $7,000.00
$8,000.00 cost per press cost per day cost per month Dollars
Dollars
12. Stillages Relocation
13. Before
14. After
15. Stillages Time (Minutes)Before After
16. Cost Justification (Stillages) Previous average time 8
minutes Current average time 1.4 minutes Total time saved 6.6
minutes Stillage changes per day 4 Time saved per press / day 26.4
0.44 of an hour Press overhead rate $130 Dollars Total savings per
press/day $57.20 Dollars Total number of presses 7 Total saving per
day $400.40 Dollars Total savings per month $8,008.00 Dollars
Stillages
17. Cost Justification
18. Cost Justification $57.20 $400.40 $8,008.00 $0.00 $1,000.00
$2,000.00 $3,000.00 $4,000.00 $5,000.00 $6,000.00 $7,000.00
$8,000.00 $9,000.00 cost per press cost per day cost per month
Dollars Dollars
19. Overtime Reduction Justification Scrap Bins Minutes Hours
Average time saved per press/day 33 0.55 Ave. No of parts made per
press 590 parts per press in 0.55 hours 324 Total Parts for 7
presses/day 2,268 Parts/week 11,340 Parts/month 45,360 Parts Parts
Parts Parts
20. Overtime Reduction Justification coil change Minutes Hours
Average time saved per press/day 22.2 0.37 Ave. No of parts made
per press 590 parts per press in 0.37 hours 218 Total Parts for 7
presses/day 1,526 Parts/week 7,630 Parts/month 30,520 Parts Parts
Parts Parts
21. Overtime Reduction Justification Stillages Minutes Hours
Average time saved per press/day 26.4 0.44 Ave. No of parts made
per press 590 parts per press in 0.44 hours 259 Total Parts for 7
presses/day 1,813 Parts/week 9,065 Parts/month 36,260 Parts Parts
Parts Parts
24. Cevol Stillages Currently Hired 37 of the type D Stillages
80 of the SM1 Stillages Half of the SM1 Stillages (shown in the
picture) can possibly be returned due to drop in Ford volumes.
25. SM1 Stillages not in use
26. Cevol Currently Hired Stillages 80 of the SS1 type
Stillages. 19 of the SS3 type Stillages. Half of the SS1 type
Stillages can be replaced by Backwells (PressFast) SS1 Stillages
which require modification.
27. Backwells (PressFast) SS1 Stillages Shown here are the
Backwells Stillages that can be modified to replace the hired
Stillages.
28. Possible 50% savings on Hired Stillages Total current cost
of hired Stillages is $1,075/month. A Savings of $500/month is
possible by replacing the SS1 and returning the SM1 type
Stillages.
29. Project Benefits Total Savings of $20-25,000 a month. An
end to the overtimes Continuous production process and Forklift
availability issues. Data collection improved and can be used for
further analysis and improvements. Employees Awareness. Less work
load for press operators. Health and safety issues and
standards.