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OCG Chicago: Kaizen EventSmall Turning (Mazak)

July , 2013

Overton Chicago GearPROCESS-DRIVEN PRECISION

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Kaizen Event Goals

• 5S audit score improvement (100%)• S/U reduction (List opportunities only)• Productivity improvement (30%)• Floor space reduction (10%) • Safety / Ergo improvements (4+)• Standard work (5S checklist)• Quality improvement (1)

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Kaizen Event Team

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Kaizen Event Team• Chris Boudreau – Event Sponsor

• Nick Charbonnier – Team Leader

• Terry Miller – Team Sub-Leader

• Cesar Lopez – Team member

• Rico Walton – Team member

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Lean Team Training

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Total Possible = 60 Points

Pre-project 5S Score: 1.25 S

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Pre-project state: Pic

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Mazak Current State

Unused rack, plastic hanging, improper outlet

use, wires & hoses

Bars & rods improperly stored and not labeled.

Storage on top of machines, tables have unneeded items,

no labels, etc.

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Mazak Current State

Unsafe table & unneeded items.

Drill press not needed & parts missing label ID

Various unnecessary items including skid of old jaws…

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RED Tagging: Remove unnecessary itemsOut of service machine & jaws

Drill press & unsafe table

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Kaizen Newspaper (Action list)

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Lean Team Hard at WorkMoving, Cleaning, Painting, Organizing

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Lean Team Hard at WorkMoving out obsolete equipment. Cleaning, Painting, racks & tables

Standardized BLUE color

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Improvements

Changed 2-socket outlet to 4-socket to eliminate

improper adapters

Added Eye Wash station.

Cleaned machine, drilled hole in cover and replaced onto machine.

Fixed loose machine gages and hanging cover.

Replaced air hoses running on floor to hard piped air supply and coil hose.

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More improvements

Moved machine created raw material staging area and cleared walking aisles.

Cleaned, painted and labeled bar storage rack.

Chip barrel on wheeled cart unblocks back of machine access and easier to move. Added material boxes on

floor and replaced anti-fatigue mats

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Cleared walking aisles.

Painted walls & posts according to OCG standard, labeled

shelving and repaired water hose reel.

More improvements

Non-Conforming part box

More Labels

Added Fire Extinguisher

Safety stripping

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NVA Time Study (unload / load part) & Improvements: Chip rake above door

Air gun/hose hanging at “Point of Use”.

Raw part ready at machine.

Was 45 Seconds

Avg.

Now 17 Seconds

Avg.

NVA Time: 36, 48, 44, 53 --> Avg. = 45 Seconds

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Pre-project state: Pic

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Post-project state: Pic

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Post-project 5S Score: 3.42 S

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Sustain: Daily 5S Checklist

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Kaizen Achievements• Productivity improvement (NVA time reduction) by 62%

– Raw parts ready at machine, air hose hanger location & chip raking.• Set up improvement. Setup time delay list was developed by

the team and will be addressed separately. – Replaced missing micrometers and allocated storage space within the

work area. (setup time delay)– Adding bore gages to the work cell area. (setup time delay)

• 16 % Floor space reduction: Removed old machine and moved storage cabinet to create new space for raw material. (freed up 81 of 500 Sq. Ft.)

• Improved 1 quality issue: I.D. oversize problem has many potential root causes, but the primaries were addressed. Bore gages available in work area, Adding a “G” identifier on the part drawing to clarify when grinding stock is required, etc.

• 8 safety items, 100% complete. Opening up a walking aisle in work area makes for a safer environment.

• Created Daily 5S check-sheet for Small Turn – Mazak area• Improved 5S score from 1.25 to 3.42 (137 %).

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30 Day Follow-up Tasks

• Purchase missing micrometers. (Terry)

• Organize & issue dial bore gages. (Terry)

• Receive & issue RED non-conforming containers. DONE

• Complete new electrical outlet install. DONE

• Install Fire Extinguisher, apply red tape on floor and paint “Line of Sight” DONE

• Determine other actions relating to Set up time and ID bore problem issues. (Chris B.)

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Special Thanks to:• Danny Lyons• Dennis Koukounaras• Stanley Konopka• Pete Rygula• Miguel (Papo) Cortes• Jose Dominguez

• And anybody else we forgot.

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Lessons Learned• Time to clean and paint walls was too long.• Most improvements were completed quickly.• OCG team has enough talent to tackle most any

project.• Team works well to complete agreed upon &

assigned actions.• White walls and clean windows are good. • Improved 5S level shows other improvement needs

more clearly.• Improvement breeds excitement and participation.• First Kaizen event sets standard for additional

projects.

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