GOOD MORNING AND WELCOME

GOOD MORNING AND WELCOME

Intro Patrick Carlson Consolidated Precision Products (Minneapolis Operation) Responsible Level 3 for Non-Destructive Testing

LEAN MANUFACTURING IN AN ALUMINUM / MAGNESIUM FOUNDRY WITH FOCUS ON FLUORESCENT PENETRANT INSPECTION.

Topics of Discussion Lean Tools & Methodologies Relationship between Lean & Six Sigma View a casting through the foundry prior to and after a Lean event. Implementation & Challenge we faced View our new Lean Fluorescent Penetrant Line

LEAN MANUFACTURING What is Lean? A set of principles, concepts and techniques designed for a relentless pursuit in the elimination of waste. Producing an efficient just-in-time production system, that will deliver to our customers exactly what they need, when they need it, in the quantity they need, in sequence, without defects, and at the lowest possible cost.

The Reasons: WHY USE LEAN? To meet customer commitments To remain competitive To improve product quality To increase profitability

Our Journey to Lean? We need to know there are three types of activities or work. - Customer value added- adds form & function, customer will pay for. Final Inspections - Business non-value added- you you have to have it, customer unwilling to pay for. In-process Inspections - Non-value added Waste We must Eliminate The Waste -NVA

Lean Mfg Tools & how we used them Pull rather than push system The product flow is set by someone downstream turning to someone upstream and signaling Give me another one. (Kanban) The goal is a smooth flow of products, with all departments of the production floor supporting one another. We always know what is upstream via daily production meetings, not allowing parts to just sit. We also use a dollars per day approach. XX dollars must move each day to keep pace and meet our customer commitments. We implemented Kanban Lanes for part organization and visual inventory.

Prior to Lean parts were pushed or dumped into areas

After Lean Kanban lanes were created for organization, letting the Pull occur.

Lean Mfg Tools (cont.) Elimination of waste Anything that consumes resources but creates no value is waste. Types of waste TimeTime Eliminate delays, setups, and downtime Transportation- should add value Complexity Complex solutions create problems

Detour- Road Closed closing the aisle created delays, down time and extra movement

After Lean - New Saw & Grind Area simple, one direction flow with less down time

After Lean - New Saw & Grind reduced movement

Lean Mfg Tools (cont.) Types of waste (cont.) Labor Eliminate unnecessary movement of people Overproduction Produce only what the customer demands Space Use only the space you need

Old Salvage lost floor space & unnecessary movement in and out of the room

After Lean less space & movement with an increase of 50% capacity, from 4 to 6 stations

FPI Prior to Lean Wasted Space, baskets, skids, & junk storage

After Lean- Penetrant / Visual Inspect reduced space, transportation & labor with increased quality

Lean Mfg Tools (cont.) Types of waste (cont.) Defects Strive to eliminate rework Materials Reduce scrap and excess inventory - Implemented Quality at the Source - perform a sample inspection of the lot. - Implemented Quality Clinic- reduce defects by corrective and preventive action

Quality Clinic: defect reduction corrective & preventive action.

Lean Mfg Tools (cont.) Types of waste (cont.) Energy Use equipment and people only to make something Idle Materials Nothing just sits Labor Eliminate unnecessary movement of people

Comparison of the Old vs. New Etch / FPI Areas

Old Alum. FPI Line - excess labor & movement using a hoist system, & limited capacity

Old FPI Line limited capacity created delays

Old FPI Line - excess movement & labor unloading, reloading parts

Old Mag. Etch / FPI Line prior to lean, two separate lines existed, 2 of everything.

New Alum. Etch Line simple layout / operation using the space needed

New Mag. Etch Line one location, with multi skilled flexing operators

New FPI Line - easy operation, visual controls, with increased capacity

New FPI Line - easy operation, visual controls, with increased capacity

New FPI Line - easy operation, visual controls, with increased capacity

New FPI Line - easy operation, visual controls, with increased capacity

Lean Manufacturing Methodologies 5 S + 1 S General housekeeping principles Safety (+1 S ) Sort, what do you really need for the job? Simplify- can this be made simpler? Sweep- Keep the area clean and organized Standardize- equipment, tools, & processes Sustain- keep on track, do not go back to this is how we used to do it

Lean Mfg Methodologies we use Work Cells- consolidated areas, saw, grind, & finishing, etch, FPI, targeting. Accelerated Improvement Workshops (AIW)= PPI Teams, Product & Process Improvement teams Multiskilling flexing operators / cross training Kanbans having lanes & organization Mistake Proofing Root Cause / Corrective & Preventive Action

Lean Mfg Methodologies we use Super Markets a designated area we pull our work from. Visual Controls flags, timers, & templates. Flow relocated operations or systems. Total Productive Maintenance be pro active and schedule time. Just In Time monitor dollars per day to keep on track with customer commitments.

Lean Manufacturing & Six Sigma (The Relationship) Lean (Manufacturing Cycle) + Six Sigma (Measure of Quality) = $ (Profitability)

Lean Manufacturing & Six Sigma LeanLean (The Relationship ) Eliminate waste Work concentration Pull rather than push Pace based on demand Six Six Sigma Reduce variation Continual process improvement Defect Reduction Cost Reduction

Lean Manufacturing & Six Sigma ResultsResults (The Relationship cont.) Reduced Inventory Reduced Operational Expenses Increased Throughput & Product Quality Increased Profits & Capacity An Engaged Workforce

Factory Layout (2006 vs. 2008)

2006 Facility Map Focus; saw, grind, finishing, welding, rework, Etch & FPI

2008 Facility Map; consolidated saw, grind, finishing, weld, rework, Etch & FPI

MRB CAGE Defect Review Area 2006 Material Flow Magnesium Item #902794 Input Housing SANDBLAST PRESSURE TEST METAL STORAGE POUR IN PLACE ALUMINUM POUR-OFF PIPE MAKE FLAMMABLE STORAGE HIB SAND DUNGEON MAGNESIUM MELTING BAKE-OUT DEGREASE SAW ALUMINUM MELTING BAKE-OUT 10 SHAKE OUT SMOKE-OFF TUNNEL COLD BOX 1 SMOKE-OFF 9 TUNNEL 8 CORE STORAGE 2 DRUM 7 STORAGE MAG RE-RAP HEAT 24 TREAT FPI/ETCH Clinic X-RAY FINISHING/ PROFILE 11 12 14 HEAT TREAT SPECIAL PROCESS MEN X-RAY GRIND TARGET STRAIGHTEN 5 CORE ASSEMBLY 6 17 19 26 20 MAG13 FINISHING 18 15 27 Target 21 22 23 CNC MACHINE SHOP 4 NO BAKE 2 MAG FPI 16 25 HEAT TREAT #6 FINISHING/PROFILE HEAT TREAT LAYOUT X-RAY WELDING OFFICE SHIPPING TARGET 31 RIGGING Approximately 50 minutes of travel time (@ 1 MPH) CMM ROOM MEN 28 31 process steps (without rework) 30 1 29 CHILLS Estimated 4,459 ft. traveled GATING (0.85 miles) Office 43 PATTERN STORAGE 1 3 MAINTENANCE MAINTENANCE RECEIVING TOOL CRIB FORK LIFT REPAIR

44 2008 Material Flow Magnesium Item #902794 Input Housing 16% Reduction per part Upstream: 34 process steps (without rework) Estimated 3,745 ft. traveled (0.70 miles) Approximately 42 minutes of travel time (@ 1 MPH)

Lean Manufacturing Advantages The The Characteristics of a Lean Organization: Efficient use of assets Short time to market Short flow times High quality products Motivated work force

Lean Mfg - Challenges? Large single parts vs small multiple pieces per melt, level loading, allowing the Pull to occur. Scrap,, ensuring we produce the correct quantity, not moving extra product just to sit on it. Castings take up large floor space and create the unneeded inventory. Rework,, how long it takes to get parts through will vary, keeping in mind our customer commitments.

FPI Processing