Current Operator Load vs. 85% of TAKT

Transcription

1 Current Operator Load vs. 85% of TAKT Seconds/Safe Operator Operator Load 85% of process cycle time 85% of process cycle time 85% of process cycle time Page 1

2 If you need one safe every 18.9 seconds, Why don t you run the chain so that one safe comes off every 18.9 seconds? This would be feet per minute with 3 eyebolt apart spacing. Is this possible? If you did this, and spaced all the safes 3 eye bolts apart then you would be producing to takt time. Fabrication End: Cycle Time Calculations Chain Speed as main driver Chain Speed Small Unit Cycle Time ( a unit every 2 eyebolts) Big Unit Cycle Time (a unit every 3 eye bolts) Cycle Time (2500 Small to 300 Big) Available Minutes= 920- Minutes lost due to gaps (145 small hook spaces) TAKT Time considering demand of 2800 Cycle time as a % of TAKT time Expected # of units to be produced at 85% TRS % % % % % % % % % % % % % % % % 2852 Assumes NO downtime Chain Speed Small Unit Cycle Time ( a unit every 3 eyebolts) Big Unit Cycle Time (a unit every 3 eye bolts) Cycle Time (2500 Small to 300 Big) Available Minutes= 920- Minutes lost due to gaps (145 small hook spaces) TAKT Time considering demand of 2800 Cycle time as a % of TAKT time % % % % Assumes 10% additional downtime

3 Chain Speed Small Unit Cycle Time ( a unit every 3 eyebolts) Big Unit Cycle Time (a unit every 3 eye bolts) Cycle Time (2500 Small to 300 Big) Available Minutes= 920- Minutes lost due to gaps (145 small hook spaces) TAKT Time considering demand of 2800 Cycle time as a % of TAKT time % % % % Assumes 15% additional downtime Chain Speed Small Unit Cycle Time ( a unit every 3 eyebolts) Big Unit Cycle Time (a unit every 3 eye bolts) Cycle Time (2500 Small to 300 Big) Available Minutes= 920- Minutes lost due to gaps (145 small hook spaces) TAKT Time considering demand of 2800 Cycle time as a % of TAKT time % % % % How fast can the chains arrive and prefill still keep up? 1 every 11 seconds Operator Times for 1.2 L. Safe: Operator 1: Time Current Set up: Produce 2800 safes per day (chain at 11.8 ft/min) Grab Doors 1.77 Total Time Waiting Time Cycle Time 85% of TAKT Walk to Conveyor/Cart 1.32 Operator 1: Place Doors on Conveyor 2.51 Operator 2: Walk Back to Chain Operator 3: Grab Safe 1.17 Operator 4: Walk to Conveyor 2.54 TOTAL: # of Ops: 3.98 Place Safe 1.04 Seconds to eliminate: 8.58 Hot Melt Check 0.27 TOTAL TIME Current Set up: Produce 2650 safes per day (chain at 11.2 ft/min) Process Cycle Total Time Waiting Time Time 85% of Process Cycle Time Operator 2: Time Operator 1: Grab and Place Plastic 4.0 Operator 2: Grab and Insert Screw 6.3 Operator 3: Advance Line 1.0 Operator 4: Restock/Break Cardboard 1.75 TOTAL: # of Ops: 3.78 TOTAL TIME 13.0 Seconds to eliminate: 5.75 Operator 2: Different Method Time

4 Insert Screw 2.6 Change all Safes to 3 eyebolts appart: Produce 2800 safes per day (17 ft/min) Grab and place plastic 4.1 Total Time Waiting Time TAKT 85% of Process Cycle Time Advance Line 1.0 Operator 1: Restock 1.8 Operator 2: TOTAL TIME 9.5 Operator 3: Operator 4: TOTAL: # of Ops: 3.78 Operator 3: Time Seconds to eliminate: 6.57 Get Base 1.40 Get Door 0.93 Place door on base + push 3.51 Operator 2/3: Time Place liners on conveyor 4.65 Get Base 1.40 Move Cardboard 0.15 Grab and Place P 4.0 Unwrap Pallet 0.42 Restock/Break Ca 1.75 Get/Remove Cage/Tote 1.84 Get/Remove Cage 1.84 TOTAL TIME Place door on bas 3.51 TOTAL TIME Operator 4: Time Get Base 2.5 Place Insert in Safe 3.6 Wait for safe to advance* 4.1 Flip and Push Safe 1.8 Get/Remove Cage/Tote 1.84 TOTAL TIME 13.8

5 Cost Savings Cost Ergonomic Operator Improvements Time Saved another vendor moving robots Redesign Affects other work areas negatively Downtime Safety Sentry Approved Row Total Cost Savings X 6.5 Cost X 5.5 Ergonomic Improvements X 4 Operator Time Saved X 6.5 Another Vendor X 0.5 Moving Robots X 3 Redesign X 0.5 Affects Other Work Areas Negatively X 7 Downtime X 5.5 Safety X 6 Sentry Approved X 10 Column Total Sentry Approved Affects other work areas negatively Cost Savings Operator Time Saved Safety Cost Downtime Ergonomic Improvements moving robots another vendor Redesign

6 Sentry Approved No Maybe Yes Affects Other Work Areas Negatively Need to add an operator or change entire process Need to add a portion of an operator and tweak process No Impact Making other areas work easier Significantly reduces work in another area Cost Savings None Minimal Justifies itself Saves money Saves substantial money Operator Time Saved 0 seconds 0-1 second 2-3 seconds 3-4 seconds > 4 seconds Safety Adds a safety Hazard No Impact Improves Safety Cost > 10,000 < 7,000 < 3,000 < 500 No cost Downtime Increase downtime No change in Downtime Downtime Ergonomic Improvements Makes worse, adds twisting or increase NIOSH No Ergonomic Change Improves, eliminates twisting or decreases NIOSH Moving Robots All Robots Moved Most Robots Moved Some Robots Moved Few Robots Moved No Robots Moved Another Vendor Redesign multiple vendors 1 vendor no vendors Redesign Senior Redesign Sentry Design team can must complete handle No Redesign Baseline = Current set up

7 Cost Savings Cost Ergonomic Improvements Operator Time Saved Another Vendor Moving Robots Redesign Affects Other Work Areas Negatively Downtime Safety Sentry Approved Operator 1 Standardize Work methods Manipulate chain speed to reach TAKT Train Operators in Ergonomics Install rolling Conveyor from Chain to body conveyor Operator 2 Standardize Work methods Place pallet beside operator Rearrange work cell to eliminate twisting Change pallet loading pattern Self Feeding Screw Driver Operator 3 Orient liners all in the same direction on pallet Place obvious mark on liner Install Pallet Lift Install a Step Install a turntable Standardize work methods Create stacking bases Insert a weight controlled lifting table Create Standard base storage system Add Carts and sensor to locate person Operator 4 Use a sensor to locate a person Create Standard base storage system Lower the conveyor Use a pallet jack to move heavy pallets Use Pallet lift system Place tote on rotating conveyor Other Base return conveyor Redesign Cell in "U" shape Operators 3 and 4 close together Visual markings on the floor for cages/ pallets DO NOTHING Sentry Approved Affects other work areas negatively Cost Savings Operator Time Saved Safety Cost Downtime Ergonomic Improvements moving robots another vendor Redesign Total

8 Task Rating Elimination Train Operators in Ergonomics Place pallet beside operator Standardize Work methods Orient liners all in the same direction on pallet Visual markings on the floor for cages/ pallets 3.93 Standardize work methods If the bases are stacking (Sentry is already doing) it will eliminate this problem Rearrange work cell to eliminate twisting Create Standard base storage system Create Standard base storage system Create stacking bases Sentry is implementing this as they create new bases Use a sensor to locate a person/ eliminate finger switch Standardize Work methods Manipulate chain speed to reach TAKT Can not clean large safes fast enough to do this Insert a weight controlled lifting table Place obvious mark on liner 3.61 Upon reinspectin there are clear enough indicators on liners already Install rolling Conveyor from Chain to body conveyor Add Carts and sensor to locate person Redesign Cell in "U" shape 3.40 Change pallet loading pattern Operators 3 and 4 close together 3.22 Install Pallet Lift 3.21 Eliminated by Concepts Use Pallet lift system 3.21 Eliminated by Concepts Base return conveyor 3.08 Eliminated by Concepts Self Feeding Screw Driver 3.01 Eliminated by Concepts Install a Step 2.99 Eliminated by Concepts Install a turntable 2.92 Eliminated by Concepts Place tote on rotating conveyor 2.92 Eliminated by Concepts Use a pallet jack to move heavy pallets 2.89 Eliminated by Concepts Lower the conveyor 2.33 Not Feasible DO NOTHING 2.89 Baseline