OCG Chicago : Kaizen Event Small Turning (Mazak)
description
Transcript of OCG Chicago : Kaizen Event Small Turning (Mazak)
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--OCG Confidential--
OCG Chicago: Kaizen EventSmall Turning (Mazak)
July , 2013
Overton Chicago GearPROCESS-DRIVEN PRECISION
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--OCG Confidential--
Kaizen Event Goals
• 5S audit score improvement (100%)• S/U reduction (List opportunities only)• Productivity improvement (30%)• Floor space reduction (10%) • Safety / Ergo improvements (4+)• Standard work (5S checklist)• Quality improvement (1)
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--OCG Confidential--
Kaizen Event Team
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--OCG Confidential--
Kaizen Event Team• Chris Boudreau – Event Sponsor
• Nick Charbonnier – Team Leader
• Terry Miller – Team Sub-Leader
• Cesar Lopez – Team member
• Rico Walton – Team member
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--OCG Confidential--
Lean Team Training
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--OCG Confidential--
Total Possible = 60 Points
Pre-project 5S Score: 1.25 S
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--OCG Confidential--
Pre-project state: Pic
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--OCG Confidential--
Mazak Current State
Unused rack, plastic hanging, improper outlet
use, wires & hoses
Bars & rods improperly stored and not labeled.
Storage on top of machines, tables have unneeded items,
no labels, etc.
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--OCG Confidential--
Mazak Current State
Unsafe table & unneeded items.
Drill press not needed & parts missing label ID
Various unnecessary items including skid of old jaws…
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--OCG Confidential--
RED Tagging: Remove unnecessary itemsOut of service machine & jaws
Drill press & unsafe table
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--OCG Confidential--
Kaizen Newspaper (Action list)
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--OCG Confidential--
Lean Team Hard at WorkMoving, Cleaning, Painting, Organizing
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--OCG Confidential--
Lean Team Hard at WorkMoving out obsolete equipment. Cleaning, Painting, racks & tables
Standardized BLUE color
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--OCG Confidential--
Improvements
Changed 2-socket outlet to 4-socket to eliminate
improper adapters
Added Eye Wash station.
Cleaned machine, drilled hole in cover and replaced onto machine.
Fixed loose machine gages and hanging cover.
Replaced air hoses running on floor to hard piped air supply and coil hose.
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--OCG Confidential--
More improvements
Moved machine created raw material staging area and cleared walking aisles.
Cleaned, painted and labeled bar storage rack.
Chip barrel on wheeled cart unblocks back of machine access and easier to move. Added material boxes on
floor and replaced anti-fatigue mats
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--OCG Confidential--
Cleared walking aisles.
Painted walls & posts according to OCG standard, labeled
shelving and repaired water hose reel.
More improvements
Non-Conforming part box
More Labels
Added Fire Extinguisher
Safety stripping
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--OCG Confidential--
NVA Time Study (unload / load part) & Improvements: Chip rake above door
Air gun/hose hanging at “Point of Use”.
Raw part ready at machine.
Was 45 Seconds
Avg.
Now 17 Seconds
Avg.
NVA Time: 36, 48, 44, 53 --> Avg. = 45 Seconds
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--OCG Confidential--
Pre-project state: Pic
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--OCG Confidential--
Post-project state: Pic
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--OCG Confidential--
Post-project 5S Score: 3.42 S
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--OCG Confidential--
Sustain: Daily 5S Checklist
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--OCG Confidential--
Kaizen Achievements• Productivity improvement (NVA time reduction) by 62%
– Raw parts ready at machine, air hose hanger location & chip raking.• Set up improvement. Setup time delay list was developed by
the team and will be addressed separately. – Replaced missing micrometers and allocated storage space within the
work area. (setup time delay)– Adding bore gages to the work cell area. (setup time delay)
• 16 % Floor space reduction: Removed old machine and moved storage cabinet to create new space for raw material. (freed up 81 of 500 Sq. Ft.)
• Improved 1 quality issue: I.D. oversize problem has many potential root causes, but the primaries were addressed. Bore gages available in work area, Adding a “G” identifier on the part drawing to clarify when grinding stock is required, etc.
• 8 safety items, 100% complete. Opening up a walking aisle in work area makes for a safer environment.
• Created Daily 5S check-sheet for Small Turn – Mazak area• Improved 5S score from 1.25 to 3.42 (137 %).
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--OCG Confidential--
30 Day Follow-up Tasks
• Purchase missing micrometers. (Terry)
• Organize & issue dial bore gages. (Terry)
• Receive & issue RED non-conforming containers. DONE
• Complete new electrical outlet install. DONE
• Install Fire Extinguisher, apply red tape on floor and paint “Line of Sight” DONE
• Determine other actions relating to Set up time and ID bore problem issues. (Chris B.)
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--OCG Confidential--
Special Thanks to:• Danny Lyons• Dennis Koukounaras• Stanley Konopka• Pete Rygula• Miguel (Papo) Cortes• Jose Dominguez
• And anybody else we forgot.
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--OCG Confidential--
Lessons Learned• Time to clean and paint walls was too long.• Most improvements were completed quickly.• OCG team has enough talent to tackle most any
project.• Team works well to complete agreed upon &
assigned actions.• White walls and clean windows are good. • Improved 5S level shows other improvement needs
more clearly.• Improvement breeds excitement and participation.• First Kaizen event sets standard for additional
projects.
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--OCG Confidential--