Rack Attack Anodizing - CTR

Transcription

1 Rack Attack Anodizing - CTR

2 THE RACK ATTACK Team Members: Back L-R) Don Sigurdson, Ben Catalan, Vince Hourie, Ramon Austria, David Bryngelson, Bob Douglas, Mario Lima (advisor) (Front L-R) Roger Tabelina, Marc Collette, Sharlene Quipit (advisor), Rufino Tamayao (advisor)

3 POWER CHARTER

4 POWER CHARTER Problem What is the gap? DB Turnaround time is averaging 5 days. Needs to be 2 days in order to eliminate extra lead time for anodized orders. Maximum loads per day is 9, 10 with overtime. Need to get 12 loads per day with no overtime when required. Employees in the area are new and have not been exposed to lean manufacturing.

5 POWER CHARTER True North Alignment On-time delivery Lead time reduction Productivity improvement Employee education

6 POWER CHARTER Work plan Key steps Lean overview Prepare IRS sheets and review Time study and map process Create standard work charts current process Brainstorm, value graph and develop action plan Implement improvements Trial run Adjust Trial run Standardization Presentation

7 POWER CHARTER Planned deliverables 12 loads per day through the anodizing line to give average 2 day turnaround time. SOP's to control the process. Improved productivity in the area. Employees on the area trained on and understanding cycle time reduction and waste elimination.

8 TRAINING Introduction to lean training Gemba walk IRS creation and discussion

9 CURRENT STATE BC

10 CURRENT STATE

11 CURRENT STATE VH 36.9hrs L hrs Diff Line 234 minute cycle time 45 minute process cycle time vs. 33 minute takt time required 9 loads per day Racking time study 3 people 43 minutes & 71 steps

12 Value Stream Map Current state 47 steps for a total cycle time of 234 mins = 4 hours Value added = 29% Non Value added/business necessary = 31% Non Value added = 40% Bottlenecks racking, clean through deox

13 VALUE GRAPH 40 issues generated: 18 QUICK HITS 16 GEMS 9 STRATEGIC 12 PARK

14 After Pictures DS

15 After Pictures

16 Supplier Support Worked with chemical supplier; Reduced cleaning tank time from 15 minutes to 10 minutes Improved flow through the line from cleaner tank to anodizing tank Developed process to prime the line with load completed up to deox by the end of the shift

17 SUMMARY OF RESULTS RA 151 minute cycle time 30 minute process cycle time 10% below takt 14 loads per day Racking time study 2 people minutes & 21 steps 10% more product / load

18 SUMMARY OF RESULTS Before After Improvement Cycle Time (minutes) % Process Time (minutes) % Racking hours (time study) % Racking steps % Loads / Day % Throughput increase with new flight bars 71%

19 CONTROLS

20 DB At the end of the blitz; 1. Quick hits 18 of 18 complete 2. Gems 12 of Strategic 0 of 9 Today; 1. Quick hits 18 of Gems 16 of Strategic 6 of 9 To Be Completed During Blitz AUDITOR'S ONLY Activities Assigned to: Start Date Completion date Comments Status Comments after 6 Week Blitz or 6 Week Yes ( ) Follow-Up Audit Action List or No (x) 1 Home location for pallet jacks Ramon,Roger QUICK HITS Wed B 2 Attach clamp to bucket as guide for which bucket to use Ramon,Roger Wed B 3 Modify loading table with top or extra bars new bar B 4 Clamp tightening tool to improve ergonomics Ramon,Roger Wed B 5 Define standard for draining and do CIWI Vince,David Wed B 6 CIWI for bus bar cleaning Vince,David Wed B 7 CIWI for empty carton transfer Vince,David Wed B 8 Relocate airline by steps, retractable Ben B 9 Replace shrink wrap with poly Vince,David Wed B 10 Level marking on tanks to show when low Ramon,Roger Wed B 11 Level marking on cart or table to show height limit new bar 12 Move thickness tester to QC table Ramon,Roger Wed B 13 Clamp bucket shelf on bottom part of table Marc, Ramon new bar B 14 Define standard times in tanks for bar stripping/ciwi Vince,David Wed B 15 Process audit check list David Wed B 16 SOP for load sheet travellers Vince,David Wed B 17 Plumbing and hoses for safer and efficient cleaning of tanks Ben Wed B 18 Relocate the spline rack packing and racking Ben B GEMS 1 SOP for packing in RGD to send to anodizing Vince,David Wed B 2 SOP packaging standard after anodizing Vince,David Wed B 3 Timer on cart in racking area Thur B 4 Hour by hour chart in racking area David 30-Apr Need all new flight bars first 5 CIWI for racking Vince new bar,roger B 6 New flight bar Marc,Don Wed B 7 Simulate new flight bar racking process All new bar B 8 Angle parts for improved drainage All new bar B 9 Simulate new flight bar packing process David 15-Apr 10 Define and mark locations for carts, boxes, for packing David 15-Apr 11 CIWI new packing process David 15-Apr 12 Put new timers on each tank for improved control Ramon,Roger Wed B 13 Improve process and CIWI for sanding headers David Thur B 14 Define standard when anodizer starts next load - swc Bob Wed B 15 Hoist operator shield Ben,Don Thur B 1 complete waiting for safety approval 16 Air ratchet with regulator for clamping Marc Wed B Strategic 1 Contractor fix play on hoist Don 2 Contractor fix losing air on hoist Don 3 Implement fans or blower air to quicken dry time David 4 Buy pallet jack David 5 Itemized loads by box David 6 Platform extension into loading area Maintenance 7 Returnable containers Don 8 Change the other 7 flight bars Don/MDC 9 Weld angles onto splines Marc

21 Follow-Up Did it sustain?

22 LESSONS LEARNED Bob Do as many simulations as you can Vince Narrow your search and dig deep David A lot can be accomplished with the right team members Ramon With cooperation, teamwork and execution we can accomplish our goal Don Much easier to get things done when you have a good skillset on the team Roger We had lots of improvement Ben Small improvements make a big difference Marc You think you are doing it right, but it s wrong

23 SPECIAL THANKS MDC for completing sample flight bar NTS (Chemical Supplier) for great advice Managers and supervisors for lending us their experts for a week Mario, Sharlene and Rufino for their great input and patience Terminals fabrication for letting us use their machines CME University of Manitoba

24 Questions? PRICE ANODIZING SOLUTIONS CALL TODAY FOR A QUOTE, OR ARRANGE A TOUR OF OUR FACILITY: David Bryngelson PH: (ext. #7681) anodizing@price-hvac.com 638 Raleigh Street, Winnipeg, MB Canada R2K 3Z9