Gluer project Slough-FINAL DRAFT1
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Transcript of Gluer project Slough-FINAL DRAFT1
Company Private & Confidential ASG Worldwide Page 1
Project – Gluing Speed Optimisation to
increase capacity
Company Private & Confidential ASG Worldwide Page 2
Project Scope
Use JAG 900 as the pilot line on O-Rings
only, then roll out to all lines and other
product families and machines
To increase production speeds and efficiencies on all gluers and all products within Slough
facility
Company Private & Confidential ASG Worldwide Page 3
Business Case:
•Customer Service Level is adversely affected at Q3 and Q4 due to lack of capacity at
high seasons
Capacity may be improved using Lean Six Sigma principles and
methodologies to increase throughput of individual machines on
the Finishing line. A 15% increase in speed will improve Service
Level to our customers and contribute to the bottom-line.
Company Private & Confidential ASG Worldwide Page 4
Goal Statement
•Improve Customer Service Level to over 90% at Q3 and Q4 by maximising Gluing
machine efficiencies
To use DMAIC (Define, Measure, Analyse, Improve and Control)
process to improve gluing speed, hence improving throughput
and Service Level to our customers.
Company Private & Confidential ASG Worldwide Page 6
Project Sponsor
Tony Garnish
CEO EU
ASG Group
Technical Project Support
Lance Blizzard
EU Technical Director
Lean Project Support
Fudgie Maynard
EU Process Improvement Director
Project Sponsor
Mark Bonser
General Manager
ASG Slough
Project Owner
Manny M’banugo
Lean facilitator
Project Manager
Tony Shipp
Finishing Supervisor
Project Manager
George James Factory Manager
Project Team Members
Emi; Tom
High Level Process Map (SIPOC) for Gluing machinesProcess: Process Owner:
S I OSuppliers Inputs Outputs
Ink cured product and a healthy
machineSteps Quality product on time in full Dispatch and Distribution
Tony Shipp
CP
Gluing of Die-cut boards
Process
Dispatch and Distribution
Customers/Stakeholders
Folded cartonsDie cut boards from
bobst stationDie-cutting Bobst station
Gluing of Die cut boards on the Finishing Line
Receive job from
Die-cutting
Station + Job
bag
Run and Box
Product, then
sign-off job bags
Log in job
number on
Imprint + Set-up
machine
MakeReady
Set Imprint on
Run + Print Box
label
Collect samples
+ file
Critical Factors to Effective Gluing
•Safety
•Quality Checks
•Experienced operators
•Equipment health
•Material quality
•Good Workplace Organisation
•Current Manufacturing Practices
•Make Ready
•Scheduling
Company Private & Confidential ASG Worldwide Page 10
Pressroom
100% Cure achieved on press
Measurement equipment in place
Procedure compiled and sent to team
Company Private & Confidential ASG Worldwide Page 11
Gluer
Identify baseline speed (done)
Identify Products in scope of project (done)
Build Matrix of all gluers, products etc (done)
Build Optimum labeling system
Build/develop bible of gluing specifications per job (Done – new jobs only at present)
Identify gaps (gap analysis) – (Done --- Quality checks; Quality of product to station;
planning of jobs to machines; inter-stations and interdepartmental communication;
staffing knowledge and training of Agency staff;
Define
Company Private & Confidential ASG Worldwide Page 12
Measure, Analyze and Improve Stages
Baseline Measure from 01/01/13 to 31/12/13 (Imprint Data)
Company Private & Confidential ASG Worldwide Page 13
Measure, Analyze and Improve Stages
Stage 1 – Improvement April 2014 (Imprint Data)
Company Private & Confidential ASG Worldwide Page 14
JAG 900– KPI APRIL 2014
• PERFORMANCE vs TARGETS
Jag 900 Average Running Speed 2014
-
2,000.00
4,000.00
6,000.00
8,000.00
10,000.00
12,000.00
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecAverage running (copies per hour) Running target (copies per hour)
Company Private & Confidential ASG Worldwide Page 15
JAG 900– KPI APRIL 2014
Jag 900 Average Make Ready 2014
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecAverage make ready (mins) Target make ready (mins)
• PERFORMANCE vs TARGETS
Company Private & Confidential ASG Worldwide Page 16
JAG 900– KPI APRIL 2014
Jag 900 Copies Per Manned Hour 2014
-
2,000.00
4,000.00
6,000.00
8,000.00
10,000.00
Jan
Feb
Mar
Ap
r
May Ju
n
Jul
Au
g
Sep
Oct
No
v
Dec
Copies per manned hour Copies per manned hour target
• PERFORMANCE vs TARGETS
Company Private & Confidential ASG Worldwide Page 17
JAG 900– KPI APRIL 2014
Jag 900 Lost Time 2014
0%
2%
4%
6%
8%
10%
12%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov DecLost time Lost Time Target
• PERFORMANCE vs TARGETS
Company Private & Confidential ASG Worldwide Page 18
Achievements to Date
Comparative Analysis of 2013 averages and Project period (01/04 onwards)
AVERAGE RUNNING SPEED ON JAG 900 (2013) AVERAGE RUNNING SPEED ON JAG 900 (APRIL 2014
..)
4166.52 10955.12
AVERAGE SHEETS PER HOUR ON JAG 900.(2013) AVERAGE SHEETS PER HOUR JAG 900 (APRIL 2014..)
3436.44 9221.37
AVERAGE MAKE READY MINUTES JAG 900 (2013) AVERAGE MAKE READY MINUTES JAG 900 (APRIL
2014…)
21 9
AVERAGE OVERALL MAKE READY MINUTES
FINISHING 2013
OVERALL MAKE READY MINUTES FINISHING APRIL
2014….
30 18
Company Private & Confidential ASG Worldwide Page 19
Comparative Analysis of 2013 averages and Project period (01/04
onwards)
Over 260% increase in Average Running Speed, so far on
JAG900
Nearly 270% increase in throughput
Average M/R time reduction of 12minutes on JAG900
Overall average M/R improvement of 12 minutes on all
machines, compared to 2013.
WE ARE NOW ROLLING OUT THE EFFORTS TO OTHER
MACHINES – STARTING WITH JAG-105 (09/05/14)
Company Private & Confidential ASG Worldwide Page 20
Gaps
Training for new Agency staff (approved by Mark B)
Quality Checks need to be conducted upstream. Devise a culture of 'stop and fix' issues at
each station before moving product downstream
Tighter supervision upstream and on late shift
Grouping jobs in product families and allocate to the most efficient and effective machine for
job family (matrix build in progress)
Optimize staffing and skills levels (In progress)
Gaps highlighted to ensure continual improvement