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AMT Problem Solving

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1. Students attend 8 hr workshop on Problem Solving2. Students choose a problem in classroom to solve3. Student then breaks down the steps of the problem4. Instructors and AMT Leader mentor and coach

students5. Students visualizes problem on white boards6. Students presents problem solving boards to

manufacturers7. This should also be happening on the manufacturing

floor

Classroom Instruction

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Classroom instuction

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1.) Clarify the Problem 4.) Root Cause AnalysisUltimate Goal:

Ideal Situation:

Current Situation:

Problem Statement: Downtime is over target by 15'/shift.

2.) Breakdown the problem

5.) Develop Countermeasure & 6.) See Countermeasure Through

Upper Line Process 1 causes downtime due to a shortage of Pallets 7.) Evaluate Results

3.) Target Setting

8.) Standardize Success for Processes

UPPER LINE DOWNTIME IMPROVEMENT

Meet Vehicle Plant demand for AR Engines

Maintain æ 96% R/A per shift on Final Line.

Current avg. 30' Downtime per shift on Final Line yields a 92% R/A.

30

0

5

10

15

20

25

30

35

Upper Line Downtime

30

15

0

10

20

30

40

50

60

Actual Plan

Downtime

Minutes

GAP:15' Downtime/

Shift Avg.

What When Who

1 Yokoten Buffer requirements to Alabama for AR2 12/E PE

2 Yokoten alignment Kaizen to Alabama for AR2 2/B O/S

Root Qual ProdStatus No. Countermeasure Cause Cost Resrcs Risk Risk Selected NOV DEC JANFEBWHO

Ö 1 Add 2 Stoppers before Process 1 á Û á á á á O/S

Ö 2 Change Program for Data Read/Write in Process 1 Û á á á á á O/S

Õ 3 Change Program to Operate OS Buffer in Process 1 á á á á á á O/S

Upper Line Stop Time

Over Target

Process 1

Process 7

Process 12

Pallets

Attachment Child

Pallet must travel 3 pitches to first

Process

AM-186

ZY-588

Pallet

Process 9Nutrunner

ZY-620

AM-188

N/G Seal Press Pre-Tightening

Mechanical

Electrical TBD

SBS Conveyor Mother

Buffer

No Stopper in Place

Area not designed as

Buffer

X

á

×

á

á

×

×

ZY-620

Robot

Overrun

M/C Tightening

Cycle Time

Bolt Alignment

M/C Fault

Jig Alignment

Pallet

Jig only has alignment pins on one side

Jig does not self align

N/G Tightening

Overrun

Real Tightening

ReverseTightening

Torque Under

Pre-Tighten N/G

Angle N/G

Excessive Torque between

Bolt Jig & Washer

Mis-Alignment

Contamination

Minimal Clearance

between Jig Bolt & Washer Sleeve×

á

Û

Û

×

×

á

á

×

á

á

×

á

×

á

×

á

×

×

á

× ×

á

á

×

Û

á

×

á

á

á

Final Line Stop Time

FINAL Full 20'

Process 1 Downtime Process 7 Downtime Process 12 Downtime

16

4

02468

1012141618

Full Final ~ Upper Full Final ~ Test

Final Full Time

66'

24' 23'12.5' 10' 9.5'

0

20

40

60

80

1 8/9 7 12 4 2

Upper Line Downtime BY Process

Process #Do

wn

tim

e (M

inute

s)

0

10

20

30

40

50

60

70

Process 1 Process 7 Process 9 Process 12

Problem Types By Process

Mid-Test

Final

UpperRobot Test

30'

FINAL Short 4'

FINAL

å 15'/shift

13

0

2

4

6

8

10

12

14

16

18

20Process 1 Downtime

5

0

2

4

6

8

10

Process 7 Downtime

6

0

2

4

6

8

10

Process 9 Downtime

3

0

2

4

6

Process 12 Downtime

å 9'/shift

å

å 3'/shift å

1.5'/shift

= + + +

AR Assembly Layout

Pallets N/R Faults Pallet Lifter Work Delay

13

0

2

4

6

8

10

12

14

16

18

20Downtime/Shift

5

0

2

4

6

8

10

Downtime/Shift

30

0

5

10

15

20

25

30

35

Downtime/Shift

6

0

2

4

6

8

10

Downtime/Shift

Total Reduction

<15

Mi n

ute

s

Mi n

ute

s

Mi n

ute

s

Mi n

ute

s

Mi n

ute

s

Eliminate Pallet Downtime in Process 1 by Jan. 2010

Downtime/shift Downtime/shift Downtime/shift Downtime/shiftDowntime/shift

Do

wn

tim

e (M

inute

s)

Mi n

ute

s

Mi n

ute

s

Mi n

ute

s

Mi n

ute

s

Before/After Before/After Before/After Before/After

AMT Leader coached TBP principles one on one with students

ll PROTECTED 関係者外秘Students prepared their Problem Report on Board

ll PROTECTED 関係者外秘Some benefits of using the white board:•Makes activity easy for other to see•Easy to make changes

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More benefits of using the white board:•Keeps the activity fresh when in view daily•Helps show a better picture of the program to visitors•Helps recruit new companies because they can see student activities

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More benefits of using the white board:•Develops Public Speaking skills and presentation skills.

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Other benefits of using the white board:•Save a good “example” to serve as a guide for students when preparing their own project boards.

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Questions?