Gas Nozzle Team Report Out January 31 2008

GTE

04/10/2023 GTE Company Confidential 2

January 28 – Feb 1, 2008

ARES - GTE – Simpsonville, SC

Value Stream Mapping Workshop

Outer Gas NozzleClean & Inspect



• Agenda

• Day One

• Introduction – Lean 101 – John Petak

• 20 Principles of Lean – John Petak

• 7 Concepts of Lean – John Petak

• 8 Forms of Process Waste – John Petak

• 6S System Overview – John Petak

• Introduction to “Learning to See”


• Agenda

• Day Two• Defined 22 process steps from current state – Team

• Determined Value- added vs. Non-value added - Team

• Constructed Current State Map – Team

• Material flow of Outer Gas Nozzle “Spaghetti Diagram”- Team

• Cycle Time Measurement Training “Stop Watches” Paper Airplane

• Constructed Cycle Time Diagram




• Agenda

• Day Three• Defined & constructed Future State Map – Team

• Determined Value- added vs. Non-value added - Team

• Reviewed the “Learning to See” workbook – Team

• Developed the PDCA worksheet - Team

• Constructed the Future State “Spaghetti Diagram”

• Constructed Cycle Time Diagram



• Agenda

• Day Four• Review Current & Future Maps – Team

• Recalculated Takt times to current customer demands- Team

• Learned more about Standardized Work – John Petak

• Video on Kanban Schedule with Pull Production - Team

• Cycle Time Diagrams updated with Excel

• Management Review preparation



STATION 1 2 3 4 5 6 7 8 9 10 TOTAL STATION 1 2 3 4 5 6 7 8 9 10 TOTAL STATION 1 2 3 4 5 6 7 8 9 10 TOTAL

min 45 1234 600 60 210 2149 min 45 1234 600 60 210 2149 min 0

mean 45 1234 600 60 210 2149 mean 45 1234 600 60 210 2149 mean 0

max 45 1234 600 60 210 2149 max 45 1234 600 60 210 2149 max 0

1.68 1.6752TT 2802 2802 2802 2802 2802 2802 2802 2802 2802 2802 TT 2802 2802 2802 2802 2802 2802 2802 2802 2802 2802 TT 2802 2802 2802 2802 2802 2802 2802 2802 2802 2802

CTO 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 CTO 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 CTO 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7

Observations: Anita Fortune, Scott Thomas, Chad Ridgeway, Trent Kyzer, Debbie Campbell Opr #1 - Atomizing Air Tube Opr #2 - Flouresant Penatrant Inspection Opr #3 Pressure Test Opr #4 - Press Parts Opr #5 - Air Flow


DATE: / /


DATE: / / DATE: / /

Targets for Improvements Targets for Improvements

NUMBER OF PARTS/PERSON/HOUR: 1.7 NUMBER OF PARTS/PERSON/HOUR: 1.7

CYCLE TIME DIAGRAM

NEXT TARGETFuture State VSMCurrent State VSM

GTE Gas Nozzle Clean & Inspect Value Stream Mapping

NUMBER OF PARTS/PERSON/HOUR:

45

1234

600

60

210

45

12

34

60

0

60

21

0

45

1234

600

60

210

2802 2802 2802 2802 2802 2802 2802 2802 2802

2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7

0

500

1000

1500

2000

2500

3000

1 2 3 4 5 6 7 8 9 10

_________ 100% Takt Time_________ 85% CTO

45

1234

600

60

210

45

12

34

60

0

60

21

0

45

1234

600

60

210

2802 2802 2802 2802 2802 2802 2802 2802 2802 2802

2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7 2381.7

45

1234

600

60

210

45

1234

600

60

210

45

1234

600

60

210

0

2500

1 2 3 4 5 6 7 8 9 10

_________ 85% Target_________ 100% Takt Time_________ 85% CTO


Jan Feb March April May June July Aug Sept Oct Nov Dec

1Chad Ridgeway

RFQ Open

2Debbie Campbell

RFQ Open

3Chad Ridgeway

RFQ Open

4Anita Fortune

RFQ Open

5Chad Ridgeway

RFQ Open

6Anita Fortune

RFQ Open

7 Anita Fortune RFQ Open

8 Scott Thomas RFQ Open



11 Debbie Campbell $240.00 Open

12 Chad Ridgeway $25.00 Open

13 Trent Kyzer RFQ Open

14 Scott Thomas $25.00 Open

15 Scott Thomas/Debbie CampellRFQ Open

16 Joe Palmer RFQ Open

17 Joe Palmer RFQ Open

18 Team $25.00

19

33

Total $315.00 0 0 Total Status

Current State Map Planned Start Date Actual Start Date Status:

Future State Map Finish Date Finish Date GreenTarget Achieved

Milestone Completed MilestonesYellow Target in Jeopardy

Duration Period Duration Period Red Target Missed

Business Unit/Facility: ARES Technology - Simpsonville,SCValue Stream: Gas Nozzle - Clean & InspectValue Stream Loop: 2 Vendors thru to PSMValue Stream Owner: Anita Fortune - Cell LeaderMeasurable Targets: Lead time reductionOther targets: Quality internal PPM - FTQExplanation of Current Status

No Project Single Actions OwnerImplementation

Expense ($) Target

Results ($)

Identify 22 process steps of which 6 VA (27%) versus 16 NVA (73%). Learned that the parts travel 671 feet. The identified 20 kaizen burst during current state mapping.

Actual Results($)

Time Schedule 2008 Status Due

6S shipping and receiving phase 1, 2, & 3.

Identify process to record gas nozzle serial numbers

6S NDT area phase 1, 2, & 3

6S press area phase 1, 2, & 3

Mobile cart for laptop

6S pressure test area phase 1, 2, & 3

6S pressure test fixture storage area 1, 2, & 3

6S MRB / quarantine area 1, 2, & 3

6S air flow test stand area 1, 2, & 3

6S staging area located outside air flow test stand area

Order 6 min stop watches from Accusplit.com

Cycle time data for received parts

Laptops for each cell

Cycle time data for heat treat

Order 2 min lift devices

Bring all vendors in-house

New facility

Improve the start shift

Detaildefinition für die Ampelfarben siehe Beschreibung

Bearbeiter, Datum



GTE