Standardization fixture and Scrap reduction on forging ... · Standardization fixture and Scrap...

© 2013 Eaton. All Rights Reserved.

Standardization fixture and Scrap reduction on forging press 24

VG EMEA

Bosconero Plant

January 16,17,18,19 2017

2 © 2013 Eaton. All Rights Reserved.

RIE Team

Stefania Giacometti

Opex Snr Analyst

Nauman Ali

Quality Engineer

Giovanni Basso

Preparation area

supervisor

Cristian Volta

Operator

Team

Ditta Marchiò

External Supplier

Paolo Ambrosino

Shift spv

Giuseppe Cimino

Quality Mgr

Daniel Kavanagh

CI EMEA Mgr

Marco Di Tria

Operator

Max Defilippi

Shift spv

Antonio Antonucci

Operator

Adriano Carpino

Operator


Area Profile Sheet Area Profile

Rapid Improvement Event Area Profile Team # :

Event Dates:

RIE Standardization of forging fixture to reduce scrap January 16-17-18-19th Y2017

Preliminary Objectives: Team:(Name & Function)

1) Identify and eliminate safety issues during the event Team Leader Cimino Giuseppe

2) 5S+ Improvement in the identified area Prod Basso Giovanni

3) forgin press 24 quality improvement(slugs handling/slugs segregation,restart production procedure) Qual Ali Nauman

4) improve ergonomy during setup phase CI Giacometti Stefania

5) improve process check Prod Defilippi Maxmiliano

6) revise Standard Document: 5s+ Autonomus Maintenance, Pre-shift startup; STDWork Prod Ambrosino Paolo

8) update the LSW to ensure FLL check the new standards are being Prod operatore

9) Quality process parameter control during forgin CI EMEA kavangh Danial

EHS Mauro Volpe

x x

x

x x

x x x

x

x x

Production Requirements (Takt Time): Linked to what strategic goal and High 5 Metrics?

na CONC , TRCR, OTD, FLEX,

OEE,

Process Information: Current Situation and Problems

1.the forging area need 5s improvement

2.slugs are not well identified on boxes(too hot/toocold/restart part/go after approval

3.machine parameter not always under control4. simplified documentation on work station fi is possible move to electronic form

5.no systemation approach for process check

6.std document need to be review

2016FY FL % scrap

% scrap c/o forging 0,43%

TOOLS USED TO ACHIEVE AND SUSTAIN OBJECTIVES-ELSS/CIF

VSM

5S+

STANDARD WORK

TPM

Manning Strategy

Daily Accountability

Gemba Walk

CI for everyone

LEAN MATERIAL FLOW

6 SIGMA

Process Standardisation

Visual Controls

Process Checks

101204

Scrap pcs

ADKAR

Other(Specify)PROBLEM SOLVING KAIZEN Leader Standard Work

SUR

21 23 24 25 26 27 28 29 STA

JANUARY 1,8% 2,0% 2,2% 0,8% 1,2% 1,4% 1,9% 1,7% 1,5%

FEBRUARY 1,4% 1,9% 1,7% 0,7% 0,8% 0,9% 3,0% 1,8% 1,3%

MARCH 1,6% 2,5% 2,6% 0,6% 0,8% 1,7% 2,5% 2,1% 1,6%

APRIL 2,0% 2,3% 1,8% 1,1% 1,1% 1,3% 1,8% 3,1% 1,7%

MAY 2,3% 1,9% 2,0% 0,9% 1,4% 1,4% 2,3% 2,2% 1,6%

JUNE 1,7% 1,9% 1,4% 1,0% 1,6% 1,3% 2,2% 1,8% 1,6%

JULY 1,5% 1,5% 2,1% 0,7% 1,4% 0,9% 2,0% 1,8% 1,3%

AUGUST 1,7% 1,1% 1,6% 0,8% 1,5% 1,2% 3,0% 2,2% 1,4%

SEPTEMBER 1,1% 1,2% 1,8% 0,8% 1,2% 1,0% 1,2% 2,0% 1,2%

OCTOBER 1,1% 1,4% 2,5% 0,7% 1,2% 0,9% 1,4% 1,5% 1,2%

NOVEMBER 1,5% 1,5% 2,9% 0,7% 1,0% 1,1% 2,4% 1,5% 1,3%

DECEMBER 1,1% 2,1% 2,1% 0,9% 1,2% 1,4% 2,2% 0,0% 1,4%

YTD 1,5% 1,7% 2,0% 0,8% 1,2% 1,2% 2,1% 2,0% 1,4%

SCRAP % ON PIECES


Daily Progress Target Sheet

Target

Start Target

Identify kaizens (Safety Hazard and others) and remove 0 20

Ergonomy Improvement 0 1

Update 5s+ std 0 1

Autonomus Maintenance improvement 0 1

pre-shift startup improvement 0 1

simplified current documentaion 0 1

reduce scrap on press 24 2% 1,20%

Visual Control 0 1

Process Check Improvement 0 1

LSW creation 0 1


Before Current Condition

The forging area need 5s improvement

Slugs are not well identified on boxes(too hot/toocold/restart part/go after approval

Simplified documentation on work station fi is possible move to electronic form

No systematic approach for process check

Standard documents need to be review

Current scrap rate 2%


Team Approach Approach

Day 1

• Safety Red

• Brainstorming to share improvement ideas

• Plan of Attack

Day 2 - 3

• Quality improvement focus day

• Kaizen closure

• CIF tools implementation

Day 4

• Training

• Lesson Learnt

• Follow - Up


RIE Kaizen Newspaper

Identified 15

Closed 15

Identified 27

Closed 23

SAFETY

Other

KAIZEN


5S Activities


Safety and Quality Improvements BEFORE AFTER

• Pressure gauges are without visually indentified

limits

• Graphite containers are not identified acording

to their type, risk of making mistake during filling

• The two grafite continers are positioned very

high from the floor (operator need to load the

cylined making a movement of tak above his

shoulder

• Pressure limits on gauges are more visible

• Graphite containers are indentified for each type,

eliminate the risk of mixing one with other

• The two container have been positioned in a proper

way to improve ergonomic.


Improvement made

BEFORE AFTER

• Lot of papers work documentation

spread on working table, making

confusion

• Most of paper work is going to be

move on electronic file. Operator

will work directly on PC station.


Improvement made BEFORE AFTER

• Boxes for hot and cold slugs are not identified

• Hot slug box is not covered and locked

• Possible risk of mixing good slugs with bad

• ISHIKAWA analysis also confirms the under

subject root cause box identification

• Boxes for hot and cold slugs well identified with

red and blue colour

• Hot slug box is covered, locked and equiped

with trolly


Improvement made

BEFORE AFTER

• At the exist of forging press, forged valves

exist with very high speed while they are

hot (≈ 900 C°)

• Could generating defects on valve profile,

like chipping off the materiale from head

• At the exist of forging press, a

damper has been installed to slow

down the montion of forged valves


5S+ Improvement made

BEFORE AFTER

• Forging tools are mixed up with other tools

• Risk of mistake during tool change over

• Irregular arrangement of tools and process

documents on desk

• Forging tools are divided by each type

• Process documents are calssified and

arranged


5S+ Results

BEFORE

AFTER


5S+ Improvement

BEFORE AFTER


5S+ Improvement BEFORE

AFTER


Improvement – New workplace layout

More improved

layout

Reduced the ideal time of

operator


Waste reduction on Walking

1500 steps / shift

300 steps / shift


Best Practice Sharing

• The hot slug cut

scraps box have

been replaced with a

more secure and

better ergonomic

container to handling

the scraps

• Advantages:

• Secure mixed

hot/cold slugs

• Better ergonomic as

trolley;

• 5s on shop flooe;

Solution could

be exported to

other forgin

press


Post Event Target Sheet

Start Target 1st Day 2nd Day 3rd Day 4th Day 5th Day Difference

% Increase /

Decrease

Identify kaizens (Safety Hazard and others) and remove 20 31 5 5 2 NA 4 88%

Ergonomy Improvement 1 1 1 1 0 NA completed 100%

Update 5s+ std 1 0 0 1 0 NA completed 100%

Autonomus Maintenance improvement 1 0 1 0 0 NA completed 100%

pre-shift startup improvement 1 0 1 0 0 NA completed 100%

simplified current documentaion 1 1 1 0 0 NA on-going 50%

reduce scrap on press 24 2% 1,20% NA NA NA NA NA on-going on-going

Visual Control 1 2 1 1 0 NA completed 100%

Process Check Improvement 1 0 1 0 0 NA completed 100%

LSW creation 1 0 0 0 1 NA completed 100%

Remarks: 1. move from paper sheets to electronics file with IT support

2.

3.


Learning and Sustaining

CIF Tools to sustain:

5S+, Autonomous Maintenance and Pre Shift Start Up standard improvement

Visual Control

Process Check (calendar already in place in the finishing lines) and 5S+ Audit

already in place

Standard Work and LSW updated


Improvement Plans / Next Steps

1. This solution will be tested during one

month production before possible

extension to other forging pressess

2. Layout review evaluation/optimization

of all remaining forgin press in

preparation area.


Reflection on RIE Process

Job well done

1. External suppliers cooperation

2. Team Engagement

3. Activities scheduled

4. Active operators partecipation

through shifts

Needs improvement

1. All works properly as planned

What has been

learned

1. «Key people» involved are

essentila to achive the results

Obstacles

• Work on production runninng shift

Suggestion for next RIE

1. Continue to involve operator

using suggetion board

24 © 2013 Eaton. All Rights Reserved. 24

Summary

Tools Used

VSM

5S+ X

Standard Work X

TPM X

SUR

Problem Solving Kaizen x

Lean Material Flow x

6 Sigma

Process Standardisation X

Visual Controls X

Process Checks X

Leader Standard Work X

Manning Strategy

Daily Accountability

Gemba Walk x

CI for everyone X

ADKAR

Other(Specify)

COST $ SAVINGS $

5000,00

Project Summary

Summary of Results:

•Improved standards for 5S+, Autonomous

Maintenance and Safety Checks

•Quality opportunities for improvement

•Ergonomic improvement found and implemented

•Improved 5S+ for Forging press area 24

1.000,00

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