Drill Press 09 Setup Reduction

Kaizen BlitzSeptember 9 - 13, 2002

Casey

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Objectives:• Reduce setup time by 50%

• Establish Standardized Work for Setup

• 5S the Work Cell

Casey

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Kaizen Team:• Robert Keith

• Wavell Burns

• Richard Stevens

• Peter DiCamillo

• Stanley Rate

Roger

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

• Roger Micks

• Len Burgess

• Shawn Knox

• Jaime Cintron

• Casey Bralla

Thanks to Bedford for allowing participation by their best looking, smartest, hardest working personnel.

• Lots of good cross-pollination ideas

• Helps establish “best practices” in both Bedford and Collingwood.

Roger

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Roger

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Working Together

Drill 09 Background:

• Used for Swing Rails

• Worst case setup, due to 24 drill chucks

• Lessons learned on this machine can be applied to other drills.

• Setup time had been improved last year from 40+ hours to ~ 4 hours.

Len

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Improvements Made:• Organized & 5S’d three setup carts to ensure all components are

available before setup begins.

• Changed procedures to ensure only good machine components are presented for setting up the machine.

• Improved setup sheets to list number of chucks needed to help the Stores Attendant in getting materials ready.

• Created Shadow Boards to 5S and standardize tooling locations.

• Reduced the number of different types of fasteners (only 1 wrench needed)

• Improved chuck mounting method to speed setting in place.

• 5S’d the area: Painted lines, Sorted unneeded equipment, labeled locations and equipment.

• Revised the setup SOP.

Len

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Productivity Improvements:

Wavel

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Organized and 5S’d three setup carts.

All needed components are present.

Productivity Improvements:

Wavel

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Tooling on setup cart sorted to eliminate hunting for correct tools.

Productivity Improvements:

Jaime

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Redesigned mounting method for chucks.

Improve ergonomics and speed setup.

Productivity Improvements:

Stanley

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Ergonomic strain.

Had to hold chuck in place while tightening bolt.

Productivity Improvements:

Stanley

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Redesigned mount.

Do not have to hold chuck in place while tightening.

Machine Improvements:

Shawn

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Low cost chuck supports prevent chuck from moving, & frees-up a spare chuck.

Standard Procedure Improvements:

Richard

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Red Tag:

Chuck needs repair and cannot be used.

Standard Procedure Improvements:

Richard

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Green Tag:

Chuck is OK to use.

5S’d the work cell:

• Lines mark incoming, outgoing product.

• Storage shelves for needed tooling organized and labeled.

• Safety equipment labeled.

• Unneeded equipment removed from the cell.

• Shadow boards created for hand tools and cleaning supplies.

Robert

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

5S Improvements:

Robert

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Cell layout with lines for incoming and outgoing materials.

5S / Safety Improvements:

Robert

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

“Third Arm” location established and labeled to ensure they are used efficiently.

5S Improvements:

Peter

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

All items labeled. Only needed items kept in work cell.

5S Improvements:

Peter

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Shadow board for frequently-used tools and gages.

5S Improvements:

Peter

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Frequently-used gages labeled.

5S Improvements:

Peter

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Added warning signs to machine guard.

Lean Scorecard:

Old NewChange

Setup Time 4.0 hours 1.5 hours 62%

Lead Time - - Red 2.5 hrs

Inventory - - “Big Problem”

Floorspace - -“Controlled”

Scrap - -$35/su

Pieces per man-hour No Change No Change -

Casey

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Blitz Savings:

Can make more than twice the number of setups in the same amount of time, without cost penalty.

This gives us the opportunity to reduce inventories

Casey

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

30 minute (or less) setup:• Require equipment and layout changes to get to 30 minute

setup.

• Need $63K for machine modifications (duplicate tooling for external pre-set)

• Need $50K for cranes, which can be common to many machines.

Casey

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Future Plans:• Implement 5S in other drill cells.

• Find quick change chucks (no keys needed)

• Fabricate toggle clamp for chuck supports.

• Design & Build drill preset fixture

• Design & Build improved guards to eliminate third arm.

Roger

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

Join us in the Journey!

Roger

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz

We need your help to carry forward throughout the plant.

We need fresh ideas and fresh perspectives.

We are all part of the new solution!

Thank You!

Group

Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz