--OCG Confidential-- OCG Chicago: Kaizen Event Small Turning (Mazak) July, 2013

--OCG Confidential-- Kaizen Event Goals 5S audit score improvement (100%) S/U reduction (List opportunities only) Productivity improvement (30%) Floor space reduction (10%) Safety / Ergo improvements (4+) Standard work (5S checklist) Quality improvement (1)

--OCG Confidential-- Kaizen Event Team

--OCG Confidential-- Kaizen Event Team Chris Boudreau – Event Sponsor Nick Charbonnier – Team Leader Terry Miller – Team Sub-Leader Cesar Lopez – Team member Rico Walton – Team member

--OCG Confidential-- Lean Team Training

--OCG Confidential-- Total Possible = 60 Points Pre-project 5S Score: 1.25 S

--OCG Confidential-- Pre-project state: Pic

--OCG Confidential-- Mazak Current State Unused rack, plastic hanging, improper outlet use, wires & hoses Bars & rods improperly stored and not labeled. Storage on top of machines, tables have unneeded items, no labels, etc.

--OCG Confidential-- Mazak Current State Unsafe table & unneeded items. Drill press not needed & parts missing label ID Various unnecessary items including skid of old jaws…

--OCG Confidential-- RED Tagging: Remove unnecessary items Out of service machine & jaws Drill press & unsafe table

--OCG Confidential-- Kaizen Newspaper (Action list)

--OCG Confidential-- Lean Team Hard at Work Moving, Cleaning, Painting, Organizing

--OCG Confidential-- Lean Team Hard at Work Moving out obsolete equipment. Cleaning, Painting, racks & tables Standardized BLUE color

--OCG Confidential-- Improvements Changed 2-socket outlet to 4-socket to eliminate improper adapters Added Eye Wash station. Cleaned machine, drilled hole in cover and replaced onto machine. Fixed loose machine gages and hanging cover. Replaced air hoses running on floor to hard piped air supply and coil hose.

--OCG Confidential-- More improvements Moved machine created raw material staging area and cleared walking aisles. Cleaned, painted and labeled bar storage rack. Chip barrel on wheeled cart unblocks back of machine access and easier to move. Added material boxes on floor and replaced anti-fatigue mats

--OCG Confidential-- Cleared walking aisles. Painted walls & posts according to OCG standard, labeled shelving and repaired water hose reel. More improvements Non-Conforming part box More Labels Added Fire Extinguisher Safety stripping

--OCG Confidential-- NVA Time Study (unload / load part) & Improvements: Chip rake above door Air gun/hose hanging at “Point of Use”. Raw part ready at machine. Was 45 Seconds Avg. Now 17 Seconds Avg. NVA Time: 36, 48, 44, 53 --> Avg. = 45 Seconds

--OCG Confidential-- Pre-project state: Pic

--OCG Confidential-- Post-project state: Pic

--OCG Confidential-- Post-project 5S Score: 3.42 S

--OCG Confidential-- Sustain: Daily 5S Checklist

--OCG Confidential-- Kaizen Achievements Productivity improvement (NVA time reduction) by 62% – Raw parts ready at machine, air hose hanger location & chip raking. Set up improvement. Setup time delay list was developed by the team and will be addressed separately. – Replaced missing micrometers and allocated storage space within the work area. (setup time delay) – Adding bore gages to the work cell area. (setup time delay) 16 % Floor space reduction: Removed old machine and moved storage cabinet to create new space for raw material. (freed up 81 of 500 Sq. Ft.) Improved 1 quality issue: I.D. oversize problem has many potential root causes, but the primaries were addressed. Bore gages available in work area, Adding a “G” identifier on the part drawing to clarify when grinding stock is required, etc. 8 safety items, 100% complete. Opening up a walking aisle in work area makes for a safer environment. Created Daily 5S check-sheet for Small Turn – Mazak area Improved 5S score from 1.25 to 3.42 (137 %).

--OCG Confidential-- 30 Day Follow-up Tasks Purchase missing micrometers. (Terry) Organize & issue dial bore gages. (Terry) Receive & issue RED non-conforming containers. DONE Complete new electrical outlet install. DONE Install Fire Extinguisher, apply red tape on floor and paint “Line of Sight” DONE Determine other actions relating to Set up time and ID bore problem issues. (Chris B.)

--OCG Confidential-- Special Thanks to: Danny Lyons Dennis Koukounaras Stanley Konopka Pete Rygula Miguel (Papo) Cortes Jose Dominguez And anybody else we forgot.

--OCG Confidential-- Lessons Learned Time to clean and paint walls was too long. Most improvements were completed quickly. OCG team has enough talent to tackle most any project. Team works well to complete agreed upon & assigned actions. White walls and clean windows are good. Improved 5S level shows other improvement needs more clearly. Improvement breeds excitement and participation. First Kaizen event sets standard for additional projects.

--OCG Confidential--