TWI-Integrating JI into Manufacturing Operations at Sandia National Laboratories Ed Astle Muhammad El Divina Calderon

Transcription

1 TWI-Integrating JI into Manufacturing Operations at Sandia National Laboratories Ed Astle Muhammad El Divina Calderon Sandia Corporation AT&T: Martin Marietta: Lockheed Martin: 1995 present Honeywell: Contractor commences managing after April 30, 2017 Government owned, contractor operated Federally Funded Research and Development Center (FFRDC) FFRDCs operate in the public interest with objectivity and independence, free from organizational conflicts of interest, and by maintaining core competencies in missions of national significance. 2 1

2 Mission Sandia Sites A multidisciplinary national laboratory and federally funded research and development center (FFRDC) that safeguards the nation's nuclear stockpile and provides the national security solutions for the country by anticipating and resolving emerging national security challenges innovating and discovering new technologies to strengthen the nation s technological superiority creating value through products and services that solve important national security challenges informing the national debate where technology policy is critical to preserving security and freedom throughout our world 3 Our Core Values Exceptional Service in the National Interest Serve the nation Team to deliver excellence Respect each other Act with integrity Live safe & healthy lives 4 2

3 Executive Management Organization Chart 5 Division Weapons Engineering and Product Realization Center 2100 NM Weapons Systems Engineering Center 2200 Deputy Chief Engineer/NM Stockpile Systems Center Energetic Components Center Engineering Design & Integration Center Neutron Generator Enterprise Center NW Product Engineering Program Center Stockpile Resource Center 6 3

4 Center 2700: Neutron Generator Enterprise How are we the same as the rest of Sandia? We have an unwavering commitment to National Security ( Exceptional Service in the National Interest ). How are we different? We design and produce a limited life component. We have responsibility for the entire product lifecycle of our component ( DA and PA ). We have the most advanced Lean Culture in the laboratory (Continuous Improvement, Focus on the Customer, Eliminate Waste). 7 Neutron Generator Role in Weapons Performance A neutron generator produces 14 MeV neutrons The fusion of D2 and T3 gives He4 + n MeV Neutrons must enter the pit at critical mass to initiate the fission chain reaction. Timing Reliability Neutron Generators are Miniature Particle Accelerators 8 4

5 Competencies Facilities Tools NG Product Families and Development Status Large FENG (In Production) Small FENG (In Production) ELNG (In Development) 9 Center 2700 Neutron Generators Core Competencies We design, develop, and manufacture ferroelectric and electronic Neutron Tubes (NT) and Neutron Generators (NG) Competencies Cleaning/Blasting Technologies Joining Technologies Welding, Brazing Soldering Encapsulation (Polymers) Testing (hardware/software) Analytical Services Mass Spectroscopy Neutron Detection Metallization Thin-Film Deposition Environmental Conditioning Thermal, Vibration, Mech. Shock Glass/Ceramic material Explosive Technology Applied Science & Technology Fundamental knowledge Modeling & Simulation 10 5

6 Neutron Generator Enterprise Supply Chain S&T Deliver Qualified Design to Customer SFENG Non-NG Products PPVS NT Active Ceramics NGSA Environmental Conditioning Deliver NGAs to Customers NGA Deliver Annual Assessment Report Surveillance ELNG Electronic Components Energetic Components INFRASTRUCTURE DEPARTMENTS Integrated Systems Analysis Tester Engineering Operations Management (ES&H, Facilities and Training, Calibration and Maintenance, Equipment Lifecycle Maintenance) Cyber Engineering & Technology (IT, Cyber and Physical Security, and NEA/TRUST) Analytical Technologies Business Operations (10627) 11 Training System Prior to JI Eight-hour OJT100 Course required for trainers process owners (engineers/technologist) and key operators Training accomplished a variety of ways by the process owner training at least one key operator anytime a new or modified TWD (technical work document - work instruction or operating procedure) was released A generic OJT Lesson Guide was filled in by process owner and key operator to indicate successful training and proficiency to become a trainer Training responsibility turned over to key operator using same nonstandard process 12 6

7 Training System Prior to JI 13 System Flaws 14 7

8 System Flaws No certified trainer requirements other than completion of OJT100 Course No follow-up after Course No oversight of operator training or trainer proficiency One Generic Lesson Guide (plus TWD) for every process Knowledge preservation weak Tribal knowledge used more than TWDs in many instances Training diluted over time First-time production yields < goal for several processes 15 Introduction of JI 2010 Art Smalley (President, Art of Lean, Inc. and Sandia consultant) Introduces JI to NG Management Management realizes Reasons Why vastly missing from TWDs Decision is made to try JI JI implementation assigned to staff member Core training team established Art Smalley Mentor Original Staff Member Lead One or two individuals from each production floor 16 8

9 Introduction of JI First 10-hour JI classes taught by JI Lead Team Leads Technologists Operators Pilot developed for operators to author JIBs Limited JI training begins with operators training operators 17 Introduction of JI cont d. Success was marginal Operator from Team paired with retiring SME (subject matter expert) Tribal knowledge captured using JIB methodology (MS, KP, RW) Some info used to update/modify TWDs New operator trained in three months Gaps still evident between JIBs and TWDs Actual work done by operators and documented work maintained by technologists differed Maintenance of too many documents Experiment begins with embedding JI within TWDs 18 9

10 OJT/JI Becomes Official 2014 New Lesson Plan template developed Satisfies OJT Requirements Embraces JI TWD template developed for ease of embedding JI Management split between use of JIBs or JI embedded TWDs for training 75% of the production operation departments decide on JI embedded TWDs Remaining 25% created JIBs as appendices to TWDs 19 OJT/JI Becomes Official 2016 Process of embedding JI into TWDs now taking place within all departments OJT100 course is still delivered by Sandia s Corporate Training Department Job Instruction Training of trainers and operators remains as recommended by TWI 20 10

11 Benefits of Embedding JI TWD and training documentation automatically remain aligned Standard work implementation becomes a team effort Tribal knowledge captured Maintain and Train to one document, versus several Consistency of training Easier version control of training Less time reviewing Avoidance of audit trap 21 Production Training Requirements Corporate Training Requirements: Trainers shall complete OJT100 class Six-Step OJT lesson plan shall be created and maintained for Medium and High rigor level processes OJT lesson plans are required to be followed and are auditable for Medium and High rigor level processes OJT lesson plans recommended for Low rigor level processes 22 11

12 Production Training Requirements Neutron Generator Production Training Requirements: Plus Trainers and operators shall complete 10 hr. JI training class All TWDs shall be embedded with JI along with implementation of standard work by OJT/JI trained authors One OJT lesson plan shall be created for each TWD TWD training records are maintained in Operator Training & Qualification database Cross Training Matrix is maintained to identify training gaps and management reporting

13 HOW TO GET READY TO INSTRUCT 2. BREAK DOWN THE JOB: List Major Steps Select Key Points Explain Reasons for the Key Points Safety factors are always Key Points JI embedded TWD template is utilized for this purpose 25 JI Embedded TWD Template Functionality Template Style formats for the body of the document have been predefined and can be assigned using the WI/OP Styles menu 26 13

14 JI Embedded TWD Template Functionality Text Style Examples: 27 JI Embedded TWD Template Functionality 28 14

15 JI Embedded TWD Template Functionality Printout levels and classification markings: 29 JI Embedded TWD Example 30 15

16 JI Embedded TWD Example 31 JI Embedded TWD Example 32 16

17 JI Embedded TWD Example 33 JI Embedded TWD Example 34 17

18 Symbol Codes Font: Webdings, Code: 209 Font: Verdana, Code: FFFD 35 HOW TO GET READY TO INSTRUCT 1. MAKE A TIME TABLE FOR TRAINING: Who to train For which work By what date This is accomplished with the use of training matrix And OJT/JI Training Execution Flow 36 18

19 Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8 Process 9 Process 10 Process 11 Process 12 Process 13 Process 14 Process 15 Process 16 Process 17 Process 18 Identify Training Opportunities Training gaps Quality Concern New Process New Product Status Date: January 16, 2017 Operator 1 Operator 2 Operator 3 Operator 4 Operator 5 Operator 6 Operator 7 Cross-Training Matrix Op A Op B Op C Op D S S L L S L S S L L L L L C C C C C In Training Qualified Training Follow-up Completed Goal Actual Status +/ Procedure: OJT/ JI Training Execution Flow Enter revised/ new TWD into Training Database. New TWD or major revision? No Operator trained to previous Rev.? Yes Review changes with Operator(s). Process Technologist Yes Negotiate schedule commitment for OJT/ JI Training with Team Lead, Production Planner and OJT/ JI Training Coordinator (if necessary). May be accomplished during pre-job release meeting. No Train Operator per lesson plan. Communicate progress (plan vs. actual) during daily meeting. Monitor training (every 2 metrics). OJT/ JI Training Coordinator and/ or Team Lead New Operator Assigned TWD(s) in Training Matrix & Training Database. Confirm training in Training Database. Assign Trainee Operator and Exp. Operator (if necessary) for training during AM meeting. Production Planner Provide availability of product and/ or process to train on

20 HOW TO GET READY TO INSTRUCT 3. GET EVERYTHING READY (Per OJT-JI Lesson Plan) The proper equipment, tools, materials and whatever needed to aid instruction 4. ARRANGE THE WORKSITE Neatly, as in actual working conditions

21 HOW TO INSTRUCT 1. PREPARE THE WORKER Put the person at ease State the job Find out what the person already knows Get the person interested in learning the job Place the person in the correct position (during demo) 41 OJT-JI Lesson Plan Example (Cont.) 42 21

22 OJT-JI Lesson Plan Example 43 OJT-JI Lesson Plan Example 2. PRESENT THE OPERATION Tell, show and illustrate one Major Step at a time Do it again stressing Key Points Do it again stating Reasons for key points Instruct clearly, completely and patiently, but don t give them more information than they can master at one time 44 22

23 OJT-JI Lesson Plan Example 3. TRY-OUT PERFORMANCE Have the person do the job-correct errors Have the person explain each Major Step to you as they do the job again Have the person explain each Key Point to you as they do the job again Have the person explain Reasons for key points to you as they do the job again Make sure the person understands Continue until you know they know 45 OJT-JI Lesson Plan Example Step 4 FOLLOW UP Put the person on their own Designate who the person goes to for help Check on the person frequently Encourage questions Taper off Extra coaching and close follow-up IF THE WORKER HASN T LEARNED, THE INSTRUCTOR HASN T TAUGHT (cont.) 46 23

24 OJT-JI Lesson Plan Example 47 Procedure: OJT/ JI Training Execution Flow Process Technologist Continue training until Trainee passes evaluation AND Trainer and Trainee agree training is complete. Process Technologist and Operator input completion in Training Database (if OJT was required). OJT/ JI Training Coordinator and/ or Team Lead Qualify Operator. Update Training Matrix. Perform at least one follow-up. Update Training Matrix. Complete Production Planner 48 24

25 Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8 Process 9 Process 10 Process 11 Process 12 Process 13 Process 14 Process 15 Process 16 Process 17 Process 18 Cross-Training Matrix Op A Op B Op C Op D Status Date: January 16, 2017 Operator 1 Operator 2 Operator 3 Operator 4 Operator 5 Operator 6 Operator 7 S S L L S L S S L L L L L C C C C C In Training Qualified Training Follow-up Completed Goal Actual Status +/ Questions? 50 25