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Kaizen Blitz AR coating set up reduction-October 2005

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Information about Kaizen Blitz AR coating set up reduction-October 2005
Business & Mgmt

Published on February 21, 2014

Author: AlanMagner

Source: slideshare.net

Description

3 - Day Kaizen Event focusing on AR Changeover to:
- Changeover time reduction
- Increased machine productivity, run time
- Improve cell organization
- Improve ergonomics & safety
- Clear SOPs & training materials

Achieved AUD$220,000 annual savings
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Kaizen Event – Process Improvement: AR Room SMED Processes 24-26 October, 2005 Facilitated by: Sally Ulman & Alan Magner vrisixsigma@aol.com 1

Agenda (see detailed agendas for each team) • Monday – Lean overview – Measure current state – Develop Action Item List • Tuesday – Complete Action Item List, new process map - Morning – Map new process, document improvements, SOPs – Afternoon • Wednesday – Conduct new Change over - Morning – Develop Presentation, Make Presentation @ 4pm

Leadership Support • We empower the team to make process improvements • Major changes will be reviewed and approved when possible • Time, resources and equipment will be provided • We hope most changes will occur DURING the event, all other action items will be given time to complete in the future

Kaizen Blitz Vision • Faster, Better, We Help People See. • Our aim for 2005 is to consistently deliver 48hr service to our Retail Customers from time of order to delivery back to store.

Scope of Activity • 3 - Day Kaizen Event focusing on AR Changeover to: – Changeover time reduction – Increased machine productivity, run time – Improve cell organization – Improve ergonomics & safety – Clear SOPs & training materials

AR Setup Reduction Kaizen Team Team “C.S.I.” Clean Syrus Improvement Team Members • David Fairclough • Ed Soriaga • George Webster • Facilitator: – Alan Magner

Process IPO – Syrus Clean INPUTS OUTPUTS No. of operstors to do the task Skill level of operators Level on Cleanliness (scale 1 - 5) Amount of shields to change humidity in the room Sandblast machine - pressure Sandblast machine - quality of beads scotchbrite pads, chux wipes Shield cleaning on Syrus Machine Run time Machine downtime Product mix (ultra Vs Invisibles) Ease to clean (scale 1 - 5) sequence of shield changes Frequency of cleaning The INPUTS can be found by considering the 6 M's: Manpower Methods Machines Measurement Mother Nature Materials

SMED Process • Observe cleaning process, record times • Eliminate wasted / unneeded steps • Remove duplication of tasks • Move steps from Internal to External of the setup • Simplify steps • Improve safety at every opportunity

Action Item List Amount of actions listed 28 Actions taken 20 Actions outstanding 8 Completion Rate 71%

Breakdown of Phase 1 improvement Phase 1 - Eliminate waste Total Time: 2h 30m 9s Eliminate 41% Time to eliminate: 1h 2m 18s Steps staying internal to set-up: 1h 24m 6s 43% reduction in set-up time Ext. Time 2% Steps made external to setup: 3m 45s Int. Time 57%

Phase 2 - Add 2nd person Total Time: 2h 30m 9s Time to eliminate: 1h 2m 18s Eliminate 42% Steps staying internal to set-up: 57m 32s 62% reduction in set-up time 2nd Person: 26m 34s External Time 2% Time reduction with 2nd person 18% Steps made external to set-up: 3m 45s Total Internal Time 38%

Phase 3 - Have extra shields Total Time: 2h 30m 9s Time to eliminate: 1h 2m 18s Eliminate 42% Steps staying internal to set-up: Total Internal Time 32% 47m 22s 68% reduction in set-up time 2nd Person: 36m 44s External Time 2% Time reduction with 2nd person 24% Steps made external to setup: 3m 45s

5S - Shield Trolley Shields were stacked on top of each other Before Every shield has a place After

5S - Shield Trolley Before After

Visual Control: Preparation Checklist • Have we everything we need? - easy to see

Layout - Sandblast room Before - no clear workflow After - dedicated workflow Sandblast machine Clean parts out Dirty parts in Trolley Sandblast machine Trolley Trolley for clean parts Trolley for dirty parts

Safety improvement Hard to reach the V-1 hazard Before Standing on/in machine parts to accomplish cleaning task Safe access - using ladder After Ladder now creates a safe work platform and no damage to machine parts

Error Proofing Best angle for safe cleaning & preventing machine damage Visual - not locked in place

Error Proofing Cover to prevent damage to filament during cleaning

Photo-rich SOPs

Visual Controls •Each part stamped with a unique identifier number •Each number is also the sequence number for inserting the shields

Making the changes

Minute for Syrus Clean Track & Sustain 180 162 160 1st attempt at new procedure: 43m 40s 150 140 Minutes 120 100 80 60 44 40 20 0 6-Oct 11-Oct 26-Oct Minute to clean 31-Oct 5-Nov 10-Nov Goal (60 mins) 15-Nov 20-Nov 25-Nov 30-Nov Stretch Goal (45 mins) 5-Dec

Set-Up Results Set-Up Times for Syrus Clean 3:00:00 2:30:09 2:30:00 2:00:00 1:24:06 1:30:00 0:57:32 1:00:00 } Saved 1h 42m 47s per clean 0:47:22 68% 0:30:00 reduction 0:00:00 Before Kaizen Removing Wasted Steps 2 People Extra Shields

$$ Savings AR Room : •2 Syrus coaters •Each are cleaned 6 times / month •Cleans / Year = 144 times •Hourly revenue = $900 (160 lenses @ 40mins) •Revenue = $15 per minute of downtime •Opportunity, every minute reduction in cleaning time results in an annual saving of $2160 per minute

$$ Savings Phase 1 Improvements : •eliminated waste and unnecessary steps Saved 1h 6m 3s per clean $142,560 p.a. 44% reduction Phase 2 Improvements : •Have 2 people do clean together Saved 1h 32m 37s per clean 62% reduction $198,720 p.a.

$$ Savings Phase 3 Improvements : •Extra shields & parts Saved 1h 42m 47s per clean 68% reduction $220,320 p.a.

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