1. Drill Press 09 Setup Reduction Kaizen Blitz September 9 - 13, 2002 Casey Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

2. Objectives: Reduce setup time by 50% Establish Standardized Work for Setup 5S the Work Cell Casey Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

3. Kaizen Team: Robert Keith Wavell Burns Richard Stevens Peter DiCamillo Stanley Rate Roger Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Roger Micks Len Burgess Shawn Knox Jaime Cintron Casey Bralla

4. Thanks to Bedford for allowing participation by their best looking, smartest, hardest working personnel. Lots of good cross-pollination ideas Helps establish “best practices” in both Bedford and Collingwood. Roger Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

5. Roger Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Working Together

6. Drill 09 Background: Used for Swing Rails Worst case setup, due to 24 drill chucks Lessons learned on this machine can be applied to other drills. Setup time had been improved last year from 40+ hours to ~ 4 hours. Len Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

7. Improvements Made: Organized & 5S’d three setup carts to ensure all components are available before setup begins. Changed procedures to ensure only good machine components are presented for setting up the machine. Improved setup sheets to list number of chucks needed to help the Stores Attendant in getting materials ready. Created Shadow Boards to 5S and standardize tooling locations. Reduced the number of different types of fasteners (only 1 wrench needed) Improved chuck mounting method to speed setting in place. 5S’d the area: Painted lines, Sorted unneeded equipment, labeled locations and equipment. Revised the setup SOP. Len Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

8. Productivity Improvements: Wavel Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Organized and 5S’d three setup carts. All needed components are present.

9. Productivity Improvements: Wavel Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Tooling on setup cart sorted to eliminate hunting for correct tools.

10. Productivity Improvements: Jaime Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Redesigned mounting method for chucks. Improve ergonomics and speed setup.

11. Productivity Improvements: Stanley Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Ergonomic strain. Had to hold chuck in place while tightening bolt.

12. Productivity Improvements: Stanley Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Redesigned mount. Do not have to hold chuck in place while tightening.

13. Machine Improvements: Shawn Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Low cost chuck supports prevent chuck from moving, & frees-up a spare chuck.

14. Standard Procedure Improvements: Richard Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Red Tag: Chuck needs repair and cannot be used.

15. Standard Procedure Improvements: Richard Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Green Tag: Chuck is OK to use.

16. 5S’d the work cell: Lines mark incoming, outgoing product. Storage shelves for needed tooling organized and labeled. Safety equipment labeled. Unneeded equipment removed from the cell. Shadow boards created for hand tools and cleaning supplies. Robert Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

17. 5S Improvements: Robert Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Cell layout with lines for incoming and outgoing materials.

18. 5S / Safety Improvements: Robert Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz “Third Arm” location established and labeled to ensure they are used efficiently.

19. 5S Improvements: Peter Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz All items labeled. Only needed items kept in work cell.

20. 5S Improvements: Peter Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Shadow board for frequently-used tools and gages.

21. 5S Improvements: Peter Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Frequently-used gages labeled.

22. 5S Improvements: Peter Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz Added warning signs to machine guard.

23. Lean Scorecard: Old NewChange Setup Time4.0 hours1.5 hours62% Lead Time -- Red 2.5 hrs Inventory -- “Big Problem” Floorspace --“Controlled” Scrap --$35/su Pieces per man-hourNo ChangeNo Change - Casey Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

24. Blitz Savings: Can make more than twice the number of setups in the same amount of time, without cost penalty. This gives us the opportunity to reduce inventories Casey Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

25. 30 minute (or less) setup: Require equipment and layout changes to get to 30 minute setup. Need $63K for machine modifications (duplicate tooling for external pre-set) Need $50K for cranes, which can be common to many machines. Casey Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

26. Future Plans: Implement 5S in other drill cells. Find quick change chucks (no keys needed) Fabricate toggle clamp for chuck supports. Design & Build drill preset fixture Design & Build improved guards to eliminate third arm. Roger Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz

27. Join us in the Journey! Roger Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz We need your help to carry forward throughout the plant. We need fresh ideas and fresh perspectives. We are all part of the new solution!

28. Thank You! Group Backyard ProductsDrill Press 09 Setup Reduction Kaizen Blitz