Pallet Car Change-Out ImprovementKaizen

(Kaizen- to tear apart and make better)

www.magnetation.com

February 20, 2015

The TEAM

Evan Mills

Lisette Johns

Mark Kelley

Wolf Solomon

Brian Grimes

Project Targets: 30 days and 6 Months1. Current State “Do It Now’s”2. Future State Ideal, “As Should Be”

• Eliminate all Safety Hazards- 100% – As measured by count of hazards: pinch points,

etc. • Eliminate all unnecessary Wasted time by

100% (short cuts are NOT an option)– As measured by seconds, from grate stop to grate

start.

Training!

The Team Takes Care of the Team

• Mark and his sweetheart candy– Love, Evan and Lisette!

• We couldn’t pull people off of the 5S activity!• Challenged each other, especially during

problem solving brainstorming time. • Team Tackled the Coffee Maker!

Workplace Organization Improvements, 5sWolf

Before and After

Before and After

Before and After

Before and After

Before and After

Safety ImprovementsLisette

• Original Count of Concerns:36• Current Count of Concerns based on

STANDARD WORK (do not vary from standard work!): 20

• 44% reduction in risks

Standard Work InstructionsMark

Brian- tell us how it’s supposed to be!Future Designs

What’s the ROI to pay for all this? Where’s the House $ come from?

Evan

Move this Metric!

5 min avg to 4 min avg• Standard Work

– Data tells us 4 minute C/O has been done recently. So it exists, it can be.

– However our AVG time is 4.92 minutes.

– Our RANGE is 4:00 – 7:15 minutes.

– Why? Variation between how each one is done is the biggest reason.

4 min avg to 3 min avg• The rest of the inefficiency

as defined by our sub process stop-watch– Engineering/ physical changes

Value Add vs Non-Value Add

30 Days or Less Master List

• Easel paper hanging up

6 month Master List

• Hands off• 3 minutes

# Xs Description Parking Lot Validation Strategy Vital Validation Results & Comments

Brief description of the potential Design Y/N

How will we validate? Tools used?

Hypothesis Test, Pilot Simulation etc. Y/N

Validation conclusions; p-values; comments

Design 1 Install grating at c/o N Pilot Y

Design 2

Lengthen distance crane can travel closer to furnace N

Simulation- crane speed vs chain speed over same distance N

Design 3

Design 4

Design 5

Design 6

Potential Design Validation Strategy Summary Sheet

Project Y Engineer Out Waste and Safety Hazards

If necessary use multiple pages.

Controls

• 30 Day Follow Up• Owners• Tracking• Visual Management

How Did We Do?

• Good? Real good?!? – “As Measured By”

• 44% reduction in safety risks• $506,941.20 year gained in Furnace Uptime

(raw)• $477,741.20 year after Depreciation, gas…– This is *one year* folks. What is 5? 10?...– Sources: Pi, Videos, SME’s, Controller, CRO Reports,

Field Trips