1. Set-up Reduction Kaizen June 4,6-7,& 18th, 2013

2. Problem Statement and Goal
History of problem:
Works cells are disorganized, materials are not in close proximity to their point of use. Bottlenecks within a work center are not recognized in time to reschedule work.
Much time is wasted locating materials, fixtures, and miscellaneous supplies causing motion waste looking for needed items for production.
We cannot currently define or measure start up time.
Goal:
Document new process for set-up on CNC goal 50% improvement
5S area to reduce motion waste to reduce set-up in Saw, Fabrication and Weld.

3. Team
Craig, Rose, Tony, Chase, Rob, Stan, Greg

4. Current State CNC Set-up

5. Observations All tasks completed as Internal (while machine is off)
A lot of to and from motion from CNC to Tooling Cabinet
Time spent searching for the needed tooling
Safety issue, air hose on floor
Motion Waste = 816ft
Opportunity = 50%

6. Future State Internal (while machine is off) reduced by 53%
Total time improved by 38%
Future improvement to Internal time = 69% if the comments are implemented

7. Action Item List

8. Action Item List

9. Action Item List

10. Before & After The new Standard makes it easier to
find needed items, more organized,
less walking

11. Before & After
Moved the tan cabinet next to the Press Brake, since that is where it’s tooling is stored, removed the short green cabinet to welding where it can be better used. This created space to store the “NEXT” job for the CNC.

12. Before & After 25 ft total travel 816 ft total travel
97% reduction in motion waste

13. Before & After Easier to find and put away
The drill cabinets held worn and unorganized drill bit, boxes of drills not put away, box of paint stored unsafely. The file draws held all the jigs and spaces, both needed and unneeded. All in all it took a long time to find the needed items
Easier to find and put away

14. Before & After
Removed unneeded items making it easier to work and find items

15. Before & After
Goal is to have the fixtures labeled, in a home location, and have the home locations on the travelers. This will allow anyone to find a needed jigs.

16. Before & After
Unneeded fixtures removed, Create an index of where the jigs are stored and where they go back

17. Area of Concern
To dig out needed material required 2 operators 38 minutes for a total of 1 hr 16 minutes. This procedure takes place at a minimum three times a day for a total of 720 hrs /yr of lost production.
Safety issues:
* Standing on material
* Lack of hard hats – future rack to hold hard hats at point of use
* Straps with frays – future state visual inspection before use with a standard of good and bad

18. Observations Lost Production hours
Deburr Saw Operators (2) * (2hrs/day) = 240mins
Finish work Plasma jobs =96mins
Locate cart for use (9 oper) * (4 min)*3 times/day =108 mins
Pull stock for saw (2 oper) * (15 min) * 3 times/day = 90 mins
Find next job (4 oper) * (2 mins) * 3 times/day = 24 mins
Move stock to next ( 8 oper) * ( 2 mins) * 3 times/day = 48 mins
Unload trucks = 57 mins
Total daily (Direct labor doing Indirect Work) = 663 mins or 11 hrs
Yearly total 2,532 hrs loss to product hours

19. Lean Metric CURRENT FUTURE IMPROVMENT CNC Set-up 20.4 mins 9.5 mins
54%
5S Level in Fab
.68
2.88
5S Level in Weld
.52
1.2
Motion waste
816 25
97%

20. Lessons Learned Organization makes the job easier
We need to all start thinking SAFETY FIRST
Stan loves donuts
There is a lot of wasted time just walking around finding things
There is no space to store incoming material making it increasingly harder to get to needed material
We need to start putting dollars to requested improvements to make it easier to understand the benefits.
You can save a lot of time and money if you keep things organized