Lean A3 Report for Planning Downtime Elimination
1
A3 Report 1B. CLARIFY THE PROBLEM: Eliminate Planning Downtime from 5 Hours per Week to 0 Hours per Week by July 2012. 2. BREAKDOWN THE PROBLEM: 3. SET A TARGET (The challenge): 4. ANALYZE THE ROOT CAUSE: 5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES: 7. EVALUATE RESULTS: 8. STANDARDIZE: Next challenge: Sharing with others: Lessons Learned: Form #: F-108 - Revision Date: 02/17/201 Waste(s) Identified Transportation: Inventory: Motion: Waiting: X Overproduction: Over processing Defects Skills Unused Means of Standardization: Standard Work Visual Aids /Procedures Training X Process Audits: LPA TPM Checklist 5S Audit X Other Root Causes Selected Countermeasure Who Target Finish There is no standardization at location of packages by size and model. Providing area for packaging in shelves IC Team WK 1229 WK 1229 Separation and standardization of packages location according to the type Thiego Silva WK 1229 WK 1229 Visual identification of each location for packages Rodrigo Marques WK 1229 WK 1229 Data collection – After improvement Nattyer Nunes WK 1229 WK 1229 Key Metric to Impact: Downtime IM / FA Problem Identification: What: High Where: IM/FA When: Wk 25 ~ Wk 28 How much: 15% 1A. Opportunity: Elimination of Planning Downtime Team Member Names: Leader: Thiego Silva Site/Plant: Manaus Date:22/08/2012 Nattyer Nunes Group/Workcell/Site: STB Annual Savings (US$): Rodrigo Marques Mentor: Thiego Silva - 100% of planning Downtime is related to Lack of available package in the process. - 15% of Average Downtime IM/FA is related to Planning. - Average Downtime is 5 hours per week. Loss time Planning Downtime: Lack of available package Method Environme nt - Employees not trained about how organize the place of package - Lack of organization of the location of packages - The location of packages is not standardized - Why planning Downtime? Due lack of available package in the process - Why? Because the packages were not available when the process was requested. - Why? Because operator loses time looking for packages - Why? Due lack of organization of the packages - Why? There is no standardization at location of packages by size and model. - Operator loses time when looking for packages - Eliminate buffer and other wastes that can be solved by Planning Team. - Share this project with production leaders and stock area employees. Visual Management is an important tool. It makes problems visible. Planning Downtime Eliminated Savings MVA – Material Value Added per unit US$ 6 / unit MVA / Hour (MVA x Rate) US$ 1422 / h Plannig Downtime 5 Hours / Week Total Saving/WK US$ 7110/ Week Total Saving/Month US$ 28440 / Month High Downtime: IM / FA US$ 28440/Mon th Before After
-
Upload
rodrigo-marques -
Category
Business
-
view
1.180 -
download
3
description
A3 Report (Lean Manufacturing template for PDCA), Applied to a project to reduce line down due to lack of returnable boxes. ... Relatório em formato A3 (Template para o PDCA usado no Lean Manufacturing), aplicado a um projeto de redução de paradas de linha devido falta de embalagens vai-e-vem.
Transcript of Lean A3 Report for Planning Downtime Elimination
A3 Report1B. CLARIFY THE PROBLEM:
Eliminate Planning Downtime from 5 Hours per Week to 0 Hours per Week by July
2012.
2. BREAKDOWN THE PROBLEM:
3. SET A TARGET (The challenge):
4. ANALYZE THE ROOT CAUSE:
5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES:
7. EVALUATE RESULTS:
8. STANDARDIZE:
Next challenge:
Sharing with others:
Lessons Learned:
Form #: F-108 - Revision Date: 02/17/2012
Waste(s) Identified
Transportation:
Inventory:
Motion:
Waiting: X
Overproduction:
Over processing
Defects
Skills Unused
Means of Standardization:
Standard Work Visual Aids Global Document /Procedures
Training Other X
Process Audits:
LPA TPM Checklist 5S Audit X Other
Root Causes Selected Countermeasure Who Target Finish
There is no standardization at
location of packages by size and model.
Providing area for packaging in shelves IC Team WK 1229 WK 1229
Separation and standardization of packages location according to the type Thiego Silva WK 1229 WK 1229
Visual identification of each location for packages Rodrigo Marques WK 1229 WK 1229
Data collection – After improvement Nattyer Nunes WK 1229 WK 1229
Key Metric to Impact:
Downtime IM / FA
Problem Identification:
What: High
Where: IM/FA
When: Wk 25 ~ Wk 28
How much: 15%
1A. Opportunity: Elimination of Planning Downtime Team Member Names:
Leader: Thiego Silva
Site/Plant: Manaus Date:22/08/2012 Nattyer Nunes
Group/Workcell/Site: STB Annual Savings (US$): Rodrigo Marques Mentor: Thiego Silva
- 100% of planning Downtime is related to Lack of available package in the process.
- 15% of Average Downtime IM/FA is related to Planning.
- Average Downtime is 5 hours per week.
Loss
time
Planning Downtime:
Lack of available package
Method
Environment
- Employees not trained about how organize the place of package
- Lack of organization of the location of packages
- The location of packages is not standardized
- Why planning Downtime?Due lack of available package in the process- Why?Because the packages were not available when the process was requested.- Why?Because operator loses time looking for packages- Why?Due lack of organization of the packages- Why?There is no standardization at location of packages by size and model.
- Operator loses time when looking for packages
- Eliminate buffer and other wastes that can be solved by Planning Team.
- Share this project with production leaders and stock area employees.
Visual Management is an important tool. It makes problems visible.
Planning Downtime Eliminated
SavingsMVA – Material Value Added per unit
US$ 6 / unit
MVA / Hour (MVA x Rate) US$ 1422 / hPlannig Downtime 5 Hours / Week
Total Saving/WK US$ 7110/ Week
Total Saving/Month US$ 28440 / Month
High Downtime: IM / FA
Before After
US$ 28440/Month
