Phase II Short Form Pencil Slat Cost Reduction Initiative Industrial Technologists' Toolkit For Technical Management QS 327 Team 2: Scott Sowders, Pam Neill, David Harrison, Vanessa Malone, William Myles, John Wise, Shawn Myers

Phase II Contents: 1.Project Background 2.Course Objective 3.Phase II Overview 4.Phase II Goals 5.Phase II Methodology 6.Phase II Highlights

Project Background QS 327 Class Requirements –Fulfill assignments assigned in syllabus –Review and apply methodology in Industrial Technologists’ Toolkit for Technical Management (ITTTM) –Utilize team oriented philosophies and communication Pencil Slat Production –Process improvements need to be identified. –Cost opportunities need to be explored. –Documentation needs to be supplied to demonstrate accuracy and value in our results.

Overall Course Objectives Identify problems with pencil slat production that pertain to cost. Identify options to improve processes that yield cost savings. Complete 6 tool kit assignments (tools 19 – 24). Complete 2 phase projects. Streamline RCA and SDA documentation posting cycles. Attain scores based on benchmark of 30.

Phase II Overview Tool 22 –“Synchronous Production: Enhanced Best Practices For Change, Lean, Variation Reduction “ Tool 23 –“Failure Mode and Effects Analysis (FMEA), Quality Function Deployment (QFD), Reliability for Robust Problem Solving” Tool 24 –“Total Productive Maintenance (TPM), Safety and Ergonomics, Re- engineered Lean Environment”

Phase II Goals

Tool 22 Goals Identify wasted capacity in wooden slat cutting process. Analyze internal and external processes and operation levels Analyze WIP and Takt identifying potential wastes. Complete current Tool 22 Portfolio Attain tool score of 30 Points

Tool 23 Goals Identify options to improve cutting process at a cost reduction Quality improvement through reduction of failures and identification of causes Complete Tool 23 Portfolio ahead of schedule Improve and streamline reporting process in order to obtain score of 30 points

Tool 24 Goals Identify options to improve cutting process at a cost reduction Process and quality improvements through preventive maintenance, safety, and ergonomic initiatives Complete Tool 24 Portfolio ahead of schedule Improve and streamline reporting process in order to obtain score of 30 points

Phase II Methodology

Tool 22 Methodology OCA – Operation Capacity Analysis GBAPS – General Benchmarking/Auditing Process SOPATA – SOP and Takt Analysis

Tool 23 Methodology OPCP - On Going Process Control Plan SOGA - Standard Operation General Analysis FMEA - Failure Mode and Effects Analysis QFD - Quality Function Deployment CEAS - Characteristic Evaluation And Audit System

Tool 24 Methodology OPCP - On Going Process Control Plan SOGA - Standard Operation General Analysis GSICPC - General Safety Inspection Checklist / Perato Chart MTA - Maintenance Tracking Analysis GFAPS - General Failsafing / Auditing Process, Systems

Phase II Highlights

Tool #22 Highlights: For competitive production, data, documentation & leadership must be synchronized. Best practices for completion: Data and documentation (base of all else) Discipline (details, continuously as the 5 why’s) People (assure job security, use their ideas) Technological simplicity & waste reduction Inventory (reduce to nothing) Control quality Change (essential to be competitive)

Tool 23 Highlights Failure Mode and Effects Analysis (FMEA) Design for Product and Process Product Liability and Reliability Finite Element Analysis (FEA) Quality Function Deployment (QFD) for lean General Reliability Issues for Kaizen and FMEA

Tool 24 Highlights Basic Maintenance Requirements and Lean Service Relationships Types of Maintenance Total Productive Maintenance (TPM), Synchronous Quality for Lean Safety, Human Factors, Quality Objectives Safety and Ergonomic Management Controlling Physical Conditions for Ergonomic Enhancement

Conclusion Pencil slat project is complete. Team successfully phased the posting cycle into a more, streamlined approach. Team improved benchmark scores; tools 23 and 24 both received a perfect score of 30pts. Team process flowed smoothly which has allowed tools and portfolios to be completed prior to required due dates.