1. Kaizen Report Traffic Improvement on a Marine Terminal
11/20/13
Evergreen Terminal
Team Name: “The Lean Green Traffic Machine”
Team Members: Sharifa Batts, Peter Hsia, Robert Nuno, Aaron James, Steven Stame, Rene Licon, David Cone, Shane Morgan, & Casey Cordray
(NOTE: Sharing of this information not endorsed by Ports America) or MTC Holdings, partners or subsidiaries.)

2. Project Overview Define Objective: Benefits: Project Team:
Decrease UTR cycle time__________
from ________9 minutes 10 seconds per Cycle____________
to __________8 minutes 40 seconds per Cycle____________
for______________Entire Cycle time_____
While improving Safety & Speed.
(project y)
(current level)
(good level)
(specific area)
( constraining Y’s)
Benefits:
Improved cycle times, reduction of congestion, improve traffic safety, fewer injuries and improve outside trucker turntimes.
Project Team:
Belt: Ebony Loeb
Sponsor: Ben O’Roark/Dave Wear
MBB: Ebony Loeb
Controller: Jill Bennett
Champion: Peter Dunton
Team Members: Sharifa Batts, Peter Hsia, Robert Nuno, Aaron James, Steven Stame, Rene Licon, David Cone, Shane Morgan, & Casey Cordray
1) The Objective statement should be the same as that on the charter. The Y, baseline and target should be stated.
2) Benefits should mention a $ figure and where the $ came from
3) Project Team should mention names and titles of core team

3. Team: The Lean Green Traffic Machine
Front Row: Peter Hsia, Aaron James, Sharifa Batts, Rene Licon, Robert Nuno, Back Row: Shane Morgan, Steven Stame, David Cone, & Casey Cordray

4. Safety First
SAFETY DOESN’T HAPPEN BY ACCIDENT!

5. Define Summary: DMAIC
We utilized the DMAIC process to find a permanent solution to minimize the cycle time of UTRs and Outside Truckers by improving speed, quality, safety and cost.
Define
Measure
Analyze
Improve
Control
Review Charter
Communication Plan
Collect baseline data
Develop data collection plan
Validate measurement system
Identify potential root causes
Prioritize root causes
Complete Analyze Gate
Develop potential solutions
Develop and implement pilot solution
Develop full scale implementation plan
Implement mistake proofing
Implement solution and ongoing process measurements

6. Define Summary: Traffic Improvement (Signs)
Original: UTR Driver drives to a chassis or bomb cart, drives to the crane, receives a container and a message to proceed to a Top Handler or park the container on wheels.
Original: Trucker receives a request from the Customer to pick up their container, trucker makes an appointment with the terminal, trucker goes to the in gate and asks for the container and is directed to a location in the yard to pick it up, he drives to Roto to have his chassis inspected, then he drives to the out gate for an EIR.
If necessary, summarize the findings of your project through the define phase.
Total Time: 9 minutes 10 seconds for the first UTR cycle

7. High-Level Process Map- SIPOCR
Measure
High-Level Process Map- SIPOCR
Paste and bitmap image of your SIPOC or VSM, only include summary text
We took the Suppliers, Input, Process, Outputs, Customers & Requirements and created a basic process map.

8. Detailed Process Map: Swim-Lane Map
Measure
Detailed Process Map: Swim-Lane Map
The process map can be the input/output map, the detailed process map, or both put on separate slides.
The value of the Swim-Lane Map showed us which piece of equipment was responsible for the steps in the process and how long the process took.

9. Baseline Metrics- Observation sheet (UTR)
Measure
Baseline Metrics- Observation sheet (UTR)
1) Clearly state the X’s which you will be carrying forward and the Y’s against which the X’s were evaluated
Used this sheet to figure out our baseline time for each part of the process. Took an average time.

10. Baseline Metrics- Observation sheet (Outside Trucker)
Measure
Baseline Metrics- Observation sheet (Outside Trucker)
11/19/13, 11/25/13 1st and 2nd shift
1st shift

11. Baseline Metrics- Observation sheet (Outside Trucker)
Measure
Baseline Metrics- Observation sheet (Outside Trucker)
1st shift
11/26/13 1st shift

12. Measure Summary- Graph Observations
Analyze
Measure Summary- Graph Observations
We graphed and compared the average time of each area to identify where improvements could be made.
9 minutes 10 seconds: Was the original average time it took UTR to complete a crane to crane transaction.
Longest bottleneck was the UTR driving to the chassis pit: 4 minutes and 05 seconds. The longest bottleneck for the outside trucker was from the in gate to the chassis pit: 5 minutes 45 seconds.
If necessary, summarize the findings of your project through the measure phase.

13. Value Analysis Analyze We found 4 Value Added: Outside Trucker
Roto To Out gate
UTR
Top to Crane
Crane to Top
Crane to Chassis Pit
1) Clearly state the X’s which you will be carrying forward and the main failure modes of these X’s
2) State any quick hit improvements if applicable
We took each process and determined if it was Value Added (Completed right the first time, an activity or operation performed that helps transform a product, or any activity a customer is prepared to pay for) / Non Value Added/ Necessary or Not Necessary.

14. Waste Walk- Value Time Analysis
Analyze
Value Time Analysis: UTR Crane to Crane Completed Transaction: 9 minutes 10 seconds