Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMEDSMED

March 5 - 7, 2007March 5 - 7, 2007

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED

Team Members: Mark Berninger, Brian Doll, John Mitchell, Chuck Crowder, Justin Whittle, Kris Gruner, Josh Panek, and Brandon Garrett

Team Picture

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED

BUSINESS CASEVariation in the small spinning buffing machine set-up process and the subsequent troubleshooting that often follows are two problems that if not remedied, could lead to bad quality, safety issue running the machine, unplanned machine downtime. This event will allow us to produce greater volume and variety of parts with reduced lead time - driving supply in-line with customer demand.

TARGET Reduce overall changeover time below 10 minutes Process parameters to be developed for all parts produced in Cell 4

DELIVERABLES

Standard Work Set-up Train 3 operators on kaizen team for buffing set up standard work Develop process parameters creation plan for all small spinning Audit Schedule for Monitoring Standard Work

Charter

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED

Initial Observations / Current State

Spindle/Buff changing station located too close to punch press – operator interference

Tools laid inside machine or on rack in cell

No documented parameters for buffing settings

Stack locations for new buffs on side and under machine

Quality of Buffed part is subjective

No work instructions in cell

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED

Fixtures miss ID’d in racks No Identification for fixture location No Identification of Buff fixture to part Machine being operated without internal

shields Some Fixtures missing Tools not 5S’d Oil under punch press Scrap pieces on floor

5 S Observations

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED EH&S Observations

1 Violation1 Unknown

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Created location for tooling inside machine

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED SMED Highlights

Labeled Tooling Racks & Tool Location Tags

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Developed Settings for all parts in cell

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED SMED Highlights

Part

Flange Buff

DiameterBody Buff Diameter

Body Buff Pressure

(psi)

Hand Wheel

F

Hand Wheel

B1

Hand Wheel

B2

Body Side Load Point

Body End Limit

Dwell at Side Load Point

Dwell at

End Limit

Flange Buff Max Dwell

# of Cut Passes

(w/comp)

# of Color Passes

(w/comp)

# of Color Passes

(w/o comp)

Body Compound Shots per

Stroke

Flange Compound % Volume

Cycle Time

CA22701C63 8 5 32 400 2320 2960 3.7 7.1 1 2 35 3 0 2 2 3 56

CA10601C63 8 5 32 400 2280 2900 3.7 6.8 1 2 35 5 0 1 2 3 67

CA00628S63 8 5 32 400 2320 2900 3.8 6.8 1 2 35 3 0 2 2 3 67

CA6290132B 8 5 32 360 2280 2870 3.6 5.8 3 2 0 3 0 1 2 0 47

CA23401C63 8 5 32 400 2360 3010 4.5 6.8 2 2 0 3 0 2 2 0 53

CA11001C63 8 5 32 400 2360 3010 3.8 7.1 2 2 35 3 0 2 2 3 59

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED SMED Highlights

Relocated Buff Change station

Relocated New Buff Storage

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Remove waste steps

by developing

program settings

BEFOREThese times do NOT include

spindle change out times

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AFTER

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED Basis for Improvement

Another 60 seconds could potentially be

eliminated - change PLC to accept settings by part number would give us a

total of 45% ImprovementSet-up Time Before 6.17

Set-up Time After 4.42Difference 1.75

Percent Improvement 28.4%

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED EH&S Observations

1 Violation Corrected

1 Unknown – will be corrected with newspaper item

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED

What are the key issues that could impact lack of sustainment ?

• Revisit 5S in Cell• Training of all operators• Completion of all the newspaper items• Revisit Standard Work• Weekly Audits• Quality Event - From Spun to Buffed• Shift to Shift communication

Key Success Factors

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED Report Card/Newspaper

BeforeKaizen

KaizenGoal % Improvement

AfterKaizen % Improvement

6.17 10 62.1% 4.42 -28.4%

0 6 100.0% 6 100.0%

Completion Status ECD

3/15/20073/15/20073/15/2007

3/8/20073/16/2007

4/6/20073/9/20073/9/20073/9/2007

Were any Enterprise Risk Areas affected? YES ______ NO___X____ If yes, what actions were taken to eliminate the risks?

Expected Results prior to the kaizen and opportunities after the kaizen

Remarks: Fire Extinguisher was moved but was approved by EH &S.

Event Date: 3/5/2007

Process Owner: Mike SimpsonTeam Leader: Mark BerningerArea: Small Spinning Cell 4 Buffing SMED

Expected Results Implemented Results

Process Description & Associated KPI or AIP:

Comments

4. Develop translation plan for other cells5. Install Buff rack on side panel6. PLC change for recipe called up by part number7. Label weights of Buff fixtures within cell

Newspaper Items

1. Sustainment team meeting 1 week after event2. Train all operators on all shifts3. First Cell Audit completed

8. Location for dry erase markers on rack9. Rubber hoses on end of New Buff Holders10.Kaizen Team Members: Mark Berninger, Brian Doll, John Mitchell, Chuck Crowder, Justin Whittle, Kris Gruner, Josh Panek, and Brandon Garrett

Kaizen Metrics (Targets/Goals)

Reduce overall changeover time below 10 minutesProcess parameters to be developed for all parts produced in Cell 4

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Small Spinning Cell #4 Buffing Small Spinning Cell #4 Buffing SMED SMED