1. Lean Tools - Overview Continuous Improvement Training Continuous Improvement Training Six Sigma Simplicity

2. Objectives: Learn Foundational Tools  Takt Time Calculation Sheet  Time Observation Sheet  Cycle Time / Takt Time Bar Chart  Part Process Capacity Sheet  Standard Operations: Operator Routine Sheet  Concentration / Spaghetti Diagrams  Takt Time Calculation Sheet  Time Observation Sheet  Cycle Time / Takt Time Bar Chart  Part Process Capacity Sheet  Standard Operations: Operator Routine Sheet  Concentration / Spaghetti Diagrams

3. Takt Time Calculation Sheet  Takt Time is the rate at which the customer buys the product.  Information needed for calculation:  Part number  Total Operating Time (ie. 8 hours)  Number of breaks and duration  Any other additional non-working time during a shift  Monthly production requirements  Number of working days in a month  Takt Time is the rate at which the customer buys the product.  Information needed for calculation:  Part number  Total Operating Time (ie. 8 hours)  Number of breaks and duration  Any other additional non-working time during a shift  Monthly production requirements  Number of working days in a month

4. Operating Time Part No. _____________ Number of Shifts per Day Daily Operating Time (A) min per shift X shift X 60 sec = sec per day min per shift X shift X 60 sec = sec per day min per shift X shift X 60 sec = sec per day 1 2 3 Monthly Requirements per Production Plan Number of Working Days in the Month Daily Requirement (B) = Units / DaysUnits per day Number of Shifts per day TAKT TIME Daily Operating Time (A) Daily Requirement (B) == sec per unit Daily Requirement (B) == sec per unit Daily Operating Time (A) Daily Requirement (B) == sec per unit Daily Operating Time (A) 1 2 3 Takt Time Calculation Sheet

5. Information for Example Takt Time Calculation Sheet  Information needed for calculation:  Part Number - XM-35  Total available time per shift - 8 hours  30 minute lunch break, two 10 minute breaks  10 minutes allotted for clean up  Monthly Requirement - 14,000 units  Number of days in the month – 20  Number of shifts per day - 1  Information needed for calculation:  Part Number - XM-35  Total available time per shift - 8 hours  30 minute lunch break, two 10 minute breaks  10 minutes allotted for clean up  Monthly Requirement - 14,000 units  Number of days in the month – 20  Number of shifts per day - 1

6. Example: Takt Time Calculation Sheet Part No. __XM-35___ Operating Time Number of Shifts per Day Daily Operating Time (A) min per shift X shift X 60 sec = sec per day min per shift X shift X 60 sec = sec per day min per shift X shift X 60 sec = sec per day 1 2 3 Monthly Requirements per Production Plan Number of Working Days in the Month Daily Requirement (B) = Units / DaysUnits per day Number of Shifts per day TAKT TIME Daily Operating Time (A) Daily Requirement (B) == sec per unit Daily Requirement (B) == sec per unit Daily Operating Time (A) Daily Requirement (B) == sec per unit Daily Operating Time (A) 1 2 3 14,000 20700 420 25,200 700 36

7. Procedure: Takt Time Calculation Sheet 1. Part No. - Record the appropriate part number that is being used for the calculation. 2. Operating Time - The number of hours in a shift times 60 minutes equals the total available operating time. Minus any breaks or cleanup time or any other activities that take place daily. This number equals the Operating Time. (Do not take out setup time ) 3. Daily Operating Time - The daily operating time is the time available to work in seconds per the number of shifts available to work. 4. Monthly Requirements per Production Plan - This number should be provided to you by scheduling, sales or forecasting to give you an accurate number. Be sure to look at 12 months to understand seasonality.

8. Procedure: Takt Time Calculation Sheet (Continued) 5. Number of Working Days in a Month - This is the number of days available to work in a month. Obtain this number from accounting. Make sure to get number of days for all 12 months to be able to calculate takt time for 12 months. 6. Daily Requirement - Monthly Requirements divided by Number of working days equals the daily requirement. 7. Takt Time Calculation - Takt time is calculated by number of shifts available. Daily Operating time divided by daily requirement equals takt time. Calculate takt time for the number of shifts available.

9. Time Observation Sheet

10.  Tool used to capture process / operations and break into small elements.  Establish “Most Repeatable” time per element to determine baseline measurement for performance.  Establish “Best Repeatable” time per element to determine new target for performance.  Tool used to capture process / operations and break into small elements.  Establish “Most Repeatable” time per element to determine baseline measurement for performance.  Establish “Best Repeatable” time per element to determine new target for performance.

11. Time Observation Sheet

12. Example: Time Observation Sheet 0 X

13. 0 X Write “Talk with Data" on board

14. 1.Process Name: Record the appropriate local name for the process being observed. 2. Part Number: Record the appropriate Part Number and/or Code Number that is associated with the process being observed. 3. Operator Cycle Time: Place a checkmark (√) in the box if this process is operator specific. 4. Machine: / Cycle Time: If the operation is machine specific, enter the Machine Number and place a checkmark (√) inside the Machine Cycle Time Box. 5. Date: Enter the date that the process is being observed in the space provided in the document. 6. Observer: Enter the name of the individual observing the process. Procedure: Time Observation Sheet

15. 7. Order of Operation / Element: Record the steps being performed in the appropriate numerical sequence; i.e., #1, #2, #3, #4, etc. 8. Operation / Element Description: Describe the unique step or event being observed. 9. Clock Running Time: Prior to observing the first step in the process, ensure that the stopwatch is set on zero. For the first step in the cycle, the clock running time entered will be zero. For each step thereafter, record the actual clock running time accumulated. The observer will be completing each of the clock running time boxes in a vertical manner throughout the completion of the cycles. The observer will continue this procedure for at least 10 to 12 complete cycle repetitions. 10. Elapsed Time: Upon completion of 10 to 12 observations of the complete process cycle, it will be necessary to calculate the specific elapsed times for each process step. To calculate the actual elapsed time for any given element (step), subtract the clock running time of the following element from the desired element clock running time. Example: for element #1, 9a minus 9 equals 10. Procedure: Time Observation Sheet

16. 11. Most Repeatable Operation/Element Time: In the designated box for each element of the process, record the most repeated observed time. Total the times and write the total cycle time in the box provided at the bottom of the column. 12. Best Repeatable Operation/Element Time: In the designated box for each element of the process, record the best repeated observed time. Total the times and write the total cycle time in the box provided at the bottom of the column. 13. Remarks: Any information, situation, or circumstance impacting the observation needs to be recorded in this section. 14. Cycle Time: Record in the bottom boxes the cumulative elemental elapsed times for each of the cycles that were observed. Procedure: Time Observation Sheet

17. 15’ 30’ 45’ 60’ 75’ 90’ Time Operator 1 3 4 5 2 Takt Time Cycle Time / Takt Time Bar Chart

18.  Graphical comparison of Takt Time versus operator cycle time or machine cycle time.  Determine proper manning in the work area.  Determine if machines have sufficient capacity.  Graphical comparison of Takt Time versus operator cycle time or machine cycle time.  Determine proper manning in the work area.  Determine if machines have sufficient capacity.

19. Cycle Time / Takt Time Bar Chart

20. Operations 1. Pickup material - 2 seconds 2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds 4. Ream Processing Time - 22 seconds 5. Walk to Mill machine - 4 seconds 6. Unload / Load - 10 seconds 7. Mill Processing Time - 40 seconds 8. Walk to Raw Material - 6 seconds Information for Example Cycle Time / Takt Time Bar Chart Center Drill BC-300 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 10 seconds 4. Center Drill Processing Time - 32 seconds 5. Walk to inspection table - 2 seconds 6. Inspect part and aside - 4 seconds 7. Walk to Raw Material - 2 seconds Chamfer DX-285 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 6 seconds 4. Chamfer Processing Time - 20 seconds 5. Walk to Raw Material - 2 seconds Note: Processing Time = Machine Time Only Inspect and Pack Ream DE-501 Mill XL-601

21. Process NamePart No.Prepared By MachiningXM-35 Date BEFORE GROWTTH Sum of Operators Cycle Times=78 Takt Time36 40 35 Machine Only 30 25 Operator & Machine 20 15 Operator Only 10 5 0 Seconds M. Smith 3/8/99 Takt Time = 36 seconds 12 44 Operator #1Operator #2Operator #3 = (Initial Target) 2.17 Operators Needed Constraint Bottleneck Example: Cycle Time / Takt Time Bar Chart Identifies constraint bottlenecks and manning requirements Identifies constraint bottlenecks and manning requirements.

22. Identifies capacity constraints. Example: Cycle Time / Takt Time Bar Chart

23. 1. Header Information (Process Name, Part Number, Prepared By, Date): Complete the header information as required by filling out the appropriate boxes. The information should agree with the Time Observation Sheet and the Standard Operations Routine Sheet. BEFORE CI: 2. Prepare an appropriate scale for this graph. The scale should be written in along the “Y” axis (left hand, vertical axis) of the chart. The “Y” axis will indicate the time segments, either in seconds or minutes, needed to record actual times observed for the operators and or machines. The “X” axis (horizontal line) of the chart will indicate either operators or machines. 3. At the appropriate level, draw in the Takt Time line. Procedure: Cycle Time / Takt Time Bar Chart

24. 4. Bar Charting: Create a bar chart for the total cycle time for each operator and/or machine in the process. This will be drawn in on the graph format and labeled appropriately. Each operator and/or machine will have a separate bar on the chart. Use the legend at the side of the chart to visually show if the time is: a) Machine Only, b) Operator & Machine, and c) Operator Only. 5. Calculations: In the upper right hand corner of the worksheet, the formula for the operator requirements calculation is written. It is: Operator cycle times (in total) divided by the Takt Time. Total all of the operator cycle times as charted on the Bar Chart, and place this number in the numerator portion of the equation. Write in the calculated Takt Time in the denominator of the calculation and perform the division. The quotient of this calculation is the total number of operators required. Place the quotient (total number of operators required) in the space provided under the calculation. Perform the same calculations when dealing with machines. 6. After CI: This section is handled in the same manner as described above. It should be used to display the results of the project after improvements to the process have been made. In fact this section is part of the documentation prepared to demonstrate the results of the CI activity. Procedure: Cycle Time / Takt Time Bar Chart

25. Part Process Capacity Sheet  Determine maximum output of a work center, machine group and / or cell.  Identify machine bottlenecks.  One Part Process Capacity Sheet should be calculated for all parts and all processes within the workcenter being observed.  Determine maximum output of a work center, machine group and / or cell.  Identify machine bottlenecks.  One Part Process Capacity Sheet should be calculated for all parts and all processes within the workcenter being observed.

26. Part Process Capacity Sheet  Information needed for calculation:  Process Name  Part Number  Net Operating Time and number of shifts  Daily Requirement  Time observations of machines and operators  Frequency of tool change, time per tool change, and number of pieces per tool change (Not setup)  Information needed for calculation:  Process Name  Part Number  Net Operating Time and number of shifts  Daily Requirement  Time observations of machines and operators  Frequency of tool change, time per tool change, and number of pieces per tool change (Not setup)

27. Part Process Capacity Sheet

28. Operations 1. Pickup material - 2 seconds 2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds 4. Ream Processing Time - 22 seconds 5. Walk to Mill machine - 4 seconds 6. Unload / Load - 10 seconds 7. Mill Processing Time - 40 seconds 8. Walk to Raw Material - 6 seconds Information for Example Part Process Capacity Sheet Center Drill BC-300 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 10 seconds 4. Center Drill Processing Time - 32 seconds 5. Walk to inspection table - 2 seconds 6. Inspect part and aside - 4 seconds 7. Walk to Raw Material - 2 seconds Chamfer DX-285 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 6 seconds 4. Chamfer Processing Time - 20 seconds 5. Walk to Raw Material - 2 seconds Note: Processing Time = Machine Time Only Inspect and Pack Ream DE-501 Mill XL-601

29. Information for Example Part Process Capacity Sheet  Process Name - Center Drill, Chamfer, Ream and Mill  Part Number - XM-35  Net Operating Time = 420 minutes or 25,200 seconds  One shift operation  Daily Requirement = 700 units  Tool Change Time Data:  Process Name - Center Drill, Chamfer, Ream and Mill  Part Number - XM-35  Net Operating Time = 420 minutes or 25,200 seconds  One shift operation  Daily Requirement = 700 units  Tool Change Time Data:

30. Formulas: Part Process Capacity Sheet Tool Change Time Per Piece = Time per Tool Change Number of Piece Per Tool Change Completion Time = + Manual Operation Time Machine Processing Time Daily Production Capacity = Net Operating Time Completion Time Per Piece Tool Change Time per Piece +

31. Example: Part Process Capacity Sheet

32. 1. Process Name: Record the appropriate local name of the process for which capacity is being calculated. 2. Part Number:Record the specific Part Number and/or Code Number that is associated with the process. 3. Necessary Quantity Per Day / Takt Time: Record in the box the predetermined demand quantity and Takt Time for the identified part number involved in this process. This number should be available from the facility’s Production Planning Department. 4. Net Operating Time (seconds):Record in the box the number of seconds actually available for scheduled operations. The net operating time excludes scheduled breaks, cleanup, lunch, routine meetings, etc. 5. Prepared By:Record in the specified box the name of the individual and his/her position (John Doe, supervisor) completing the PPCS. 6. Date:Record in the box the date that the sheet was completed. Procedure: Part Process Capacity Sheet

33. 7. Order of Operations:Record the steps being performed in the appropriate numerical sequence: i.e., #1, #2, #3, #4, etc. 8. Operation Description: Describe the unique step (event). 9. Machine Number (Machine No.): Enter the appropriate Machine Number or identifier in the space provided. 10. Basic Time (seconds): a) Manual Operation Time: Record the time it takes the operator to physically unload the identified part and to load a new part into the machine and begin the process. Be sure to include the time to manually operate the machine if the machine is not automatic. b) Machine Processing Time: Record the time necessary for the machine to complete one automatic cycle of the operation. This time begins with activating the start button and concludes with the part ready for unloading. c) Completion Time Per Piece: For each unique operation and machine, total the Manual Operation Time and the Machine Processing Time. Manual +Machine = Completion Time. Procedure: Part Process Capacity Sheet

34. 11. Tool Change Time (seconds): a) Change Time: Record the total number of seconds required to exchange the above mentioned tooling in the identified machine. This is not setup and/or tear-down time in changing from one part to a different part on this piece of equipment. b) Number of Pieces Per Change: Record the total number of parts or pieces that are typically produced before changing the tooling due to normal wear. This can also be used for sample runs. c) Time Per Piece: Record the quotient of Change time divided by Number of pieces per change. This establishes the time per piece required for tooling changes. 12. Total Time Per Piece: Add the Completion Time Per Piece (#10c) in the “Basic Time Category” to the Time Per Piece calculation in the “Tool Change Time Category” to derive the Total Time Per Piece. Procedure: Part Process Capacity Sheet

35. 13. Daily Production Capacity: This is the total number of units for this part that can be produced in this process during the Net Operating Time. Net Operating Time Daily Production Capacity = ______________________ Total Time Per Piece 14. Comments:This section is provided to give the user space to write pertinent comments concerning the observations. An example of a “ pertinent” comment might be the fact that a new operator is performing the tasks. This new operator may be having difficulty due to a lack of familiarity with the operation. 15. Maximum Output: In the space provided, total the maximum output for the day based on the production capacities recorded. The maximum output is equal to the output of the “most limiting” operation (the lowest number of the Daily Production Capacity). 16. Total Operator Cycle Time: Summarize the total Manual Operation Time in the Total Operator Cycle Time space provided. Procedure: Part Process Capacity Sheet

36. Standard Operations: Operator Routine Sheet  Identifies operator / machine’s work routine.  Develops the best sequence of operations for operator / machines.  Standard Operations: Operator Routine Sheet per operator in workcenter.  Identifies operator / machine’s work routine.  Develops the best sequence of operations for operator / machines.  Standard Operations: Operator Routine Sheet per operator in workcenter.

37. Standard Operations: Operator Routine Sheet

38. Operations 1. Pickup material - 2 seconds 2. Walk to Ream Machine - 2 seconds 3. Unload / Load - 20 seconds 4. Ream Processing Time - 22 seconds 5. Walk to Mill machine - 4 seconds 6. Unload / Load - 10 seconds 7. Mill Processing Time - 40 seconds 8. Walk to Raw Material - 6 seconds Information for Example Standard Operations: Operator Routine Sheet Center Drill BC-300 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 10 seconds 4. Center Drill Processing Time - 32 seconds 5. Walk to inspection table - 2 seconds 6. Inspect part and aside - 4 seconds 7. Walk to Raw Material - 2 seconds Chamfer DX-285 Operations 1. Pick up Material - 2 seconds 2. Walk to machine - 2 seconds 3. Unload / Load - 6 seconds 4. Chamfer Processing Time - 20 seconds 5. Walk to Raw Material - 2 seconds Note: Processing Time = Machine Time Only Inspect and Pack Ream DE-501 Mill XL-601

39. Procedure Standard Operations:Operator Routine Sheet 1. Header Information: a) Process Name: Enter the Process Name for the operations being charted. b) Part Number: Record the Part Number being processed. c) Employee’s Name and Position: Enter the name of the employee and the employee’s position. d) Date: Enter the date that the SOORS is being prepared. e) Necessary Quantity per Day: Enter in the space provided the customer demand required (number of units). f) Takt Time: Calculate Takt Time as follows: Net Operating Time Per Day ______________________ Units Required Per Day (Express Takt Time in seconds or minutes.) 2. Order of Operations: Record the operations being performed in the appropriate numerical sequence; i.e. #1, #2, #3, #4, etc.

40. Procedure Standard Operations:Operator Routine Sheet 3. Operation Description: Enter a complete description of each operation. 4. Basic Time: a) Manual Operation Time (seconds): Using the Part/Process Capacity Sheet, enter the time in the space provided for each step of the manual process. b) Machine Processing Time (seconds): Enter in the space provided the automatic machine processing time c) Walk Time: Enter the Walk Time in the space provided.

41. 5. Operations Time: a) Takt Time: Draw a vertical line at the appropriate point to indicate the Takt Time in seconds or minutes to fit the scale. b) Activity Plots: Using the Activity Key provided in the upper right hand column of the standard operations operator routine sheet, draw the appropriate line, in accordance with the time (seconds) required. ACTIVITY KEY Manual Operation =Solid Lines Machine Processing=Dotted Lines Waiting=Double line Walking=Wavy Line Procedure Standard Operations:Operator Routine Sheet

42. NOTES:  The Manual Operation and Machine Processing Times for the first machine are initially drawn on this sheet by taking the data from the Part/Process Capacity Sheet.  In determining subsequent operations for the operator, be sure to make time allowances for quality inspection and safety precautions.  If the final line meets the Takt Time, the operations routine is an appropriate mix.  If the final line ends before the Takt Time, determine if more operations can be added.  If the final line exceeds the Takt Time, determine ways to shorten the operations time. NOTES:  The Manual Operation and Machine Processing Times for the first machine are initially drawn on this sheet by taking the data from the Part/Process Capacity Sheet.  In determining subsequent operations for the operator, be sure to make time allowances for quality inspection and safety precautions.  If the final line meets the Takt Time, the operations routine is an appropriate mix.  If the final line ends before the Takt Time, determine if more operations can be added.  If the final line exceeds the Takt Time, determine ways to shorten the operations time. Procedure Standard Operations:Operator Routine Sheet

43. Standard Operations: Operator Routine Sheet

44. Concentration and Spaghetti Diagrams Continuous Improvement Training

45. Concentration Diagram

46. What is a Concentration Diagram?  Concentration Diagram: A simple graphical way to show frequencies of issue occurrence.  You may wish to think of it as a picture- like Fishbone  What does it do?  Non confrontational voting  Allows those doing the diagram to discover “concentrations” that may point to causes  Simply, it can help show problem areas on a product or process  Concentration Diagram: A simple graphical way to show frequencies of issue occurrence.  You may wish to think of it as a picture- like Fishbone  What does it do?  Non confrontational voting  Allows those doing the diagram to discover “concentrations” that may point to causes  Simply, it can help show problem areas on a product or process

47. Example #1 --- Concentration Diagram

48. Example #2 --- Concentration Diagram

49. Spaghetti Diagram

50. What is a Spaghetti Diagram?  Spaghetti Diagram: A simple graphical map showing the path taken by a specific product/process as it travels down the value stream process.  What does it do?  Shows process flow, and encourages team members to think in terms of relationships (multiple directions) rather than linearly  Provides an initial indication of potential cause and effect relationships  Can facilitate the emergence of key issues rather than issues from a dominant team member  Can foster discussion and challenge team assumptions about the process or area  Spaghetti Diagram: A simple graphical map showing the path taken by a specific product/process as it travels down the value stream process.  What does it do?  Shows process flow, and encourages team members to think in terms of relationships (multiple directions) rather than linearly  Provides an initial indication of potential cause and effect relationships  Can facilitate the emergence of key issues rather than issues from a dominant team member  Can foster discussion and challenge team assumptions about the process or area

51. Spaghetti Diagram  Flows of metals within a metal usage process

52. Spaghetti Charts  Functional cluster within the engineering departments lead to extensive travel of job files and engineers.  Contact between reviewer, engineer and checker require additional walking.  The layout does not encourage short communications between senior and less experienced engineers.

53. Spaghetti – Machine cell planning Reduction in travel time, waiting, WIP Improvement of ergonomics, visibility, flexibility

54. Construction tips  Project from PC onto whiteboard/flipchart and draw around image  If you expect to move furniture/machines Cut out post-its to show the plan. These can be moved easily  Apply Nominal group technique and use Post-its on a wall to build or Fishbone concentration diagram  If you have transparencies you can build up layers corresponding to different operators/processes  Photograph/Photocopy/Scan the result  Project from PC onto whiteboard/flipchart and draw around image  If you expect to move furniture/machines Cut out post-its to show the plan. These can be moved easily  Apply Nominal group technique and use Post-its on a wall to build or Fishbone concentration diagram  If you have transparencies you can build up layers corresponding to different operators/processes  Photograph/Photocopy/Scan the result

55. SummarySummary  Tools help collect and organize data.  Tools help identify areas of opportunities graphically.  All data collected will be used for the project - therefore data integrity is important.  Tools help collect and organize data.  Tools help identify areas of opportunities graphically.  All data collected will be used for the project - therefore data integrity is important.

56. Lean Tools Continuous Improvement Training