FINAL REVIEW

Elaine Mau // Professional Supply Chain Intern

Overview

� Projects

� Progress at Midpoint

� Since Midterm

� Follow-up

� Success Criteria and Milestones

� Questions

� Acknowledgement

Priority 1

FI on Line 12 Un-scrambler

Progress at Midpoint

Step 3: Analyze Causes

� Bowl Exit Chute� Where: Top and bend of chute outside the bowl

� Phenomenon: Bottles getting jammed between rail or sticking to rail

� Why 1: Worn electrical brushes on preorienter motor cause erratic stops and goes, resulting in uneven flow of bottles and therefore produced jams

� Why 2: The coating on railings caused too much friction and constricted the area in which the bottle can pass through.

� Why 3: Dimensions of the chute did not direct bottles as designed.

Step 4 & 5: Plan and implement improvement

� TBM (PM 1656) for electrical brushes

� Use spare chute

Step 6: Check Results

Results for Brushes Replaced

0

2

4

6

8

10

12

14

Bowl Exit

Chut e

Turn

Table

Flipped

Bot t les

Paddle

Wheel

Bowl

Phot oeye

Slot

Ot her Overf ill Bad

Bot t les

No

Bot t les

Baseline Brushes replaced

Step 6: Check Results

Results for Replacing Existing Chute with Line 10 Chute

0

2

4

6

8

10

12

14

16

18

Bowl Exit

Chute

Turn

Table

Flipped

Bottles

Paddle

Wheel

Bowl

Photoeye

Slot

Other Overfill Bad

Bottles

No

Bottles

Av

era

ge

Nu

mb

er

of

Sto

ps

Pe

r S

hif

t

Baseline Replaced Chute

Step 3: Analyze Causes

� Fallen Bottles� Where: On the conveyor as bottles exits the unscrambler

� Phenomenon: Bottles get stuck in the space when it falls.

� Why: Bottles have room to get stuck.

Step 4 & 5: Plan and implement improvement

� Lowered rails and centerlined

Step 3: Analyze Causes

� Turn Table� Where: As bottles flip up onto the conveyor

� Phenomenon: Bottles jams between rails and conveyor

� Why: Buckets and rails are not in correct centerlines (unmarked)

Step 4 & 5: Plan and implement improvement

� Rails moved and centerlined

Step 3: Analyze Causes

� Paddlewheel� Where: Paddle wheel

� Phenomenon: Bottles jams between rails and paddle wheel

� Why: Gap allows bottles to get stuck

Step 4 & 5: Plan and implement improvement

� Paddlewheel moved closer and centerlined

Step 6: Check Results

Final Results for FI Unscrambler Project

0

2

4

6

8

10

12

14

Bowl Exit

Chute

Turn

Table

Flipped

Bottles

Paddle

Wheel

Bowl

Photoeye

Slo t

Other Overfill Bad

Bottles

No

Bottles

Av

era

ge

Nu

mb

er

of

Sto

ps

Pe

r S

hif

t

Baseline Present

85% reduction

100%91%

Step 7: Consolidate Gains

� Replaced rail with spare chute

� Pin the paddlewheel at new position

� Pin conveyor rail to prevent fallen bottles

� Centerline turntable rails

� Unscrambler speed centerlined and added in documentation

� Centerline audit added to CIL

� Reapplication unscrambler improvements Ln 10, Ln 5

Success Criteria and Milestones

� Success Criteria

� Reduce minor stops due unscrambler from 8.33% PR (40 minutes) to 3.23% PR (15 minutes) per shift

� Milestones

� Achieved 3.03% PR (14.5 minutes) minor loss

� Significantly reduced bowl exit chute jams

� Eliminated fallen bottle and paddlewheel problems

Priority 1

Line 12 Speed Optimization Analysis

Progress at Midpoint

Results

Minor Stops

Loss

PR

Optimal Speed and Observations

� Constraint Factors

� Unscrambler

� Labeller Slugs

� Ratio of speed between each unit op.

Un-scramblerDye-

Filler/CapperLabeller Cartoner

210 207 210 216

3-4 bottles

faster

3 bottles

slower

Belt Speed:

1.00 ft/sec

Constraint

Machine

Additional Work

� Uneven bottle piles in chute� Where: Between long and short conveyor belt

� Phenomenon: Synchronization of long and short belt and eyes

� Why: Bottle material causes sticking between bottles as well as belt set-up create alternating large and small piles of bottles

Plan and implement improvement

� Electrical- Maxi-Beam Sensor Head

� Mechanical- Add-on

� Speed adjustment to make up any losses

Additional Work

� Falling bottles� Where: Between unscrambler and dye-filler/capper

� Phenomenon: Bottles fall on conveyor belt

� Why: Balance of forces from hitting against each other and from belt friction

F

F

F

FFFriction

N

Plan and implement improvement

� Cleaned to baseline condition

� Work order for missing zerk fitting and hose

� Optimal Speed: 1.00 ft/sec, posted

Actions to sustain the gain

� Centerlines posted on each equipment, belt, unscrambler

� OPL on speed analysis results

� Work order for zerk fitting tubing

Follow-up

� Unscrambler

� Ability to run faster

� Additional mechanical adjustment and replacements

� Labeller Slug Issue

� Thermal Imaging Unit

Success Criteria and Milestones

� Success Criteria

� Familiarized with line personnel

� Validated lines speeds posted on each unit op.

� Minor stops PR reduction by 2%

� Milestones

� Familiarized with line personnel

� Validated line speed posted on each unit op.

� Minor stops PR reduction by 7%

Priority 2

Line 10 Rapid Changeover

Progress at Midpoint

Step 1: Understand the Situation

Purging Bottle

Chute

Step 2 & 3: Identify improvement Ideas and plan the improvements

Step 2 & 3: Identify improvement Ideas and plan the improvements

� Separate Internal from External

� Streamline the internal

Step 2 & 3: Identify improvement Ideas and plan the improvements

� Streamline Internal

� Perform Parallel Operations

Task Sheets

� Training material to implement changes

Step 4: Implement Improvements

Step 4: Implement Improvements

� Major Loss: Bottle Dumping (up to 1½ hrs!)

�Meetings

�OPLs

� Visual Control

PLANNER LTBOTTLE DUMPER COORDINATOR

Product Labels Shippers

Bottles and

Caps

Changes in scheduleScrap material

Over/under usage

OPLs for Bottle Dumping

Visual Controls

Step 5: Check Results

Saves 31.3

Minutes!

Step 6: Consolidate Gains

� Drip pan installed

� Chutes have visual controls for bottles and caps

� OPLs for bottle dumping procedure for normal production and brand to brand change over

� Task Sheets for B/C -> Jazzing

� Reapplication- any line that requires many changeovers

Follow-up

� Continued work with bottle dumpers and line technician, Lena Dushku

� This week:

� Final Training Session (sign), planned for Tuesday, August 12th, 2008 both shifts

Success Criteria and Milestones

� Success Criteria

� Reduce c/o time from 100 minutes to 80 minutes

� Milestones

� Reduce c/o time from 100 minutes to 60-70 minutes

� Eliminated bottle excess during changeover

Priority 3

Y-Y Analysis on Line 15 Kalish Filler

Erratic fill weight for gallon bottles

� Where: Filler nozzle

� Phenomenon: Pumps do not fill bottles with consistent weights

� Why 1: Because of hot water washouts, aculyn build up causes different torques on each motor

� Why 2: Pumps gears are worn out

� Why 3: Leaking nozzles had wrong O-rings

Actions Implemented to Sustain the Gain

� Adjusted SOP to use cold DI water vs hot DI water

� Nick Dushku and Joseph Iorfino will continue validation work

� Reapply approach from line 33 developer filler to manage idle time

� This week:

� Change to new pumps

� Continue with cold water washout

Priority 3

Y-Y Analysis on Line 1 Conditioner Filler

Heating Cone Contamination on Line 1 Conditioner Filler

� Where: Heating cone

� Phenomenon: Leaking nozzles leads to contamination of heater cones

� Why 1: Leaking nozzles due to worn nozzle stems.

� Why 2: Leaking nozzles due to unsynchronized nozzle closing.

Results

� Day 1 Baseline � Week 1 Present� Day 1 Present

Actions Implemented to Sustain the Gain

� TBM from 1 year to 8 months

� Centerline

Thank you!

Travis Gombos, Karnik Patel, Joseph Deleo, Kevin Shaw, RanjithMathew

Miguel Paz, Charlie Popp, Peter Bybel, David Velez, Rocco Catalano, Jerry Talis, Geraldine Miller, Douglas, Age I., Eduardo, Tony, Marizol, Paul, Emmillianne, Lena Dushku, Mary Thompson

Bob Fitts, Eddie Lopez, Bob Flitner, Ernie, Tony, Lee Copolla, Luis, Alexis, Nestor Mendez

Any Questions?