1

Lebanon Kaizen Event #13 Hard Dies Work

March 24-28, 2008

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Team MembersName Area Service Yrs

•Team Leader: Howard Peterson Lean Tech 5 •Sub T/L: Richard Holliday Fabricator A 2•Member: Travis Officer Bass Line Hull Welder A 7•Member: Johnny Evans R&D 8•Member: Wes Wellman Fence dept. Supervisor 16•Member: Jon Meadows Fence Lead (2nd) 8•Member: Lance Schmidt Fab Lead (2nd) 9•Member: Terry McMahon R&D 18•Member: Bobby Baker Safety Manager 17•Support: Ted Edson KPO Manager 4•Consultant: Jonathan Wheatley (TBM)

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GoalsActivity Current Goal

1 One safety improvement per each team member - 9

2 Improve 5S by one point 1.5 2.5

3

4

Reduce Brake Press Set-up time 35Min 75%

Reduce WIP in Hull Fab & establish Standard WIP 86 25%

5 Write, verify & implement Standard Work 0 Complete

4

Area Layout

NIAGARA 350 T

PLASMA

UNCOILER

WELD LINE1

WELD LINE3

WELD LINE2

Supervisor Office

5

Safety Improvements

Item Description of Improvement Hazard Type Eliminated

1 Clear blocked Fire Extinguisher Fire

2 Repair Leaking fluids from the press Slip

3 Better accessibility to the Press E-Stop Crush

4 Shorten or add Coil hose Trip

5 Remove old welding curtain Trip

6 Reduce Lifting & flipping boats by hand Strain/Ergo

7 Safety block chained to Press bed (was under the table) Crush

8 Reduce number of trash cans in area Trip

9 Reduce amount of pushing carts around (Establish Standard WIP) Strain/Ergo

10 Tighten/replace guarding on Plasma machine Pinch

11 Reduce exposure to sharp edges (use hand suction cups) Cut/strain

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Improve Safety

Before:

Safety block under the table

After:

Attached safety block to bed

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Brake Press Set-Up Reduction

0

5

10

15

20

25

30

35

Op A Op B Op C Op D

CurrentExt from IntStreamlined

8

Plasma Set-Up Reduction

0

2

4

6

8

10

12

14

16

Op A Op B

CurrentExt from IntStreamlined

9

Before 5S

10

After 5S

11

Press Capability

28252219161310741

10.5

9.5

8.5

Indi

vidu

al V

alue

_X=8.917

UCL=10.017

LCL=7.816

28252219161310741

1.6

0.8

0.0

Mov

ing

Rang

e

__MR=0.414

UCL=1.352

LCL=0

3025201510

9.6

8.8

8.0

Observation

Valu

es

12.011.210.49.68.88.0

LSL USL

LSL 10USL 12

Specifications

111098

Within

Overall

Specs

StDev 0.366838Cp 0.91Cpk -0.98

WithinStDev 0.526592Pp 0.63Ppk -0.69Cpm *

Overall

1

1

Process Capability Sixpack of Bend "11"I Chart

Moving Range Chart

Last 25 Observations

Capability Histogram

Normal Prob PlotAD: 2.493, P: < 0.005

Capability Plot

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Before Material Handling

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Kaizen Improvement (Trystorming)

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Kaizen Improvement Proposal

Drawing underway

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Kaizen Improvements - Plasma

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Line Balancing

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Work In Process Current & ProposedLocation Current Proposed Delta

Hull Press Staging Area 28 16-25

Weld Line 2 Staging Area 34 5

Weld Line 3 staging Area 24 8

Totals 86 41 53%

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Operation Number: 1 of 1

SWIP

Step # Cycle Time CTQ's CTS

12345

6

78

9

10111213141516171819

Total 0

With the assistance of helper, remove cut parts from machine table onto the file table

Run another hull & after the first part is completely filed and inspected, put it on the corrugation table & cover with carpet

Repeat steps 7&8 until the daily requirement for this coil is met

Description of Work Content

Last 15 min. of shift

Clean your areaVarious

Push back the stop table in place & make sure it latches in place

Make sure the coil is in a safe position to cut the band or loosen the ratchet and do so

Standard WorkIssued by: Approval Date:Takt Time

13 Min

Feed Coil through & adjust for flatness. Keep fingers away from rollers. Wear gloves as material has sharp edges

Tony Williams 3/28/2008Safety/Hazard Controls:Tools Required:

Production Steps: Square material and select correct program. Cycle start

Set - Up Steps: Check the Decoiler & make sure it is out of gear

Model

Various

QUALITY POLICYWe are committed to delivering quality and value to our customers by; complying with customer and Quality Management System (QMS) Requirements, continuous improvement to our product and internal systems, and achieving our quality objective

PPENIAGARA 350 T

PLASMA

UNCOILER

16-25

5

8

WELD LINE1

WELD LINE1

WELD LINE1

0

Supervisor Office

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External Pre-Setup Checklist PLASMA

All Items Pre-Setup 10 Minutes Before Setup

Initial When

Complete Pre-Setup Items Responsible

Person Initial When

Complete Pre-Setup Items Responsible

Person

Coil stock & Forklift available

Plasma helper & Fork Lift driver

Ratchet with 1 -7/8 Socket

Plasma Helper

Plasma Tips Plasma Operator

PPE & Tape measure

Helper & Operator

Suction cups Helper

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ResultsActivity Current Goal Result

1 One safety improvement per each team member - 9 9 of 11 implemented

2 Improve 5S by one point 1.5 2.5 2.5

3 Reduce Brake Press Set-up time 35Min 75% 66%

4

5

Reduce Plasma Set-up time 15 75% 78%

Reduce WIP in Hull Fab & establish Standard WIP

86 25% 53%

6 Write, verify & implement Standard Work 0 1 per operator

Complete

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30 Day Items

Item Action Who When

1 Design & Fabricate hull handling equipment Terry 4/27/08

2 Post Standard work on each station Larry 4/6/08

3 Establish Press program back-up method Ted 4/6/08

4 Press positioning is not repeatable - TBD TBD

5 Implement TPM checklists for Press and Plasma Operators

Howard 4/27/08

6 Move Plasma Exhaust box out of the traffic area John/Lance 4/6/08

7 Identify and stock Long lead-time spare parts for the Press & the Plasma

Wayne King 4/6/08

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Questions?