Lean Pull System

Kaizen

Team 2Lean ManufacturingNovember 9, 2015

Team membersLorenaSylviaCathy CFacilitator: Jeff R.Claudia SRogerRhondaGemalynJoseMaria N

Team Picture

Kaizen event agenda Training Introduction - Kaizen Concepts & Process SPACER- Lean - Waste - Process Flow Analysis - Spaghetti Diagrams 2 teamsWalk the process STEPSTIME it takes to complete a part at each process

Lunch

Floor Work

- Process Flow Analysis - Spaghetti Diagrams Team Reports

Training 5STotal QualityPull SystemsPaper Air PlaneBatch ProcessOne piece flow

Lunch

Floor Work Work in your areas and evaluate how we can use 5S

Team Reports

Training Takt TimeLine BalancingCell Design Layout

5S TeamSet-upStaging

Quality TeamFirst pieceIn-process

Lunch

Floor Work Layout the workstations Evaluate Agree on the cell designTeam Reports

Training ImplementCreate CellMove benchesOrganize area

Team evaluationRe-organize if necessary

Prepare line for a production run on Friday morning

Training TEST RUN

Make any adjustments necessary

Spaghetti and time the new process

Team report out

Learn Lean

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ObjectivesCreate a competitive advantage for ICSHeighten quality awareness within the cellsEstablish 1st piece build protocolsEstablish cell set-up / start-up protocols5S cell set-up and staging racksIntroduce workforce to Lean Concepts

objetivosCrear una ventaja competitiva para el ICSAumentar la conciencia de la calidad dentro de las clulasEstablecer protocolos pieza construccin 1Establecer / protocolos de puesta en marcha celular configurar-upCelular 5S configuracin y bastidores de estadificacinIntroducir fuerza de trabajo a Lean Conceptos

Project GoalsOpportunity to increase revenue GoalOwnerFaster throughput 30%Jeff RDecreased lead-time

Higher quality yields 30 %Jeff R / Gemalyn

Production capability 30% Jeff RParts produced to FG daily

Objetivos del proyectoOportunidad para aumentar los ingresosObjetivo propietarioRendimiento ms rpido 30% Jeff RDisminucin del tiempo de entrega

Rendimientos ms altos de calidad 30% Jeff R / Gemalyn

La capacidad de produccin 30% Jeff RPiezas producidas a FG diaria

Spaghetti

Team 2 Spaghetti

Team Spaghetti Travel Waste = Motion & Transportation

Results:

Pre:Cell: Improvement:Total Steps:857108470% Astronomical!!Distance Feet:2571302541 Less TravelAmount of Time:50 min15 sec49min 45secTime SavingsComputer Trips: 12288% Fewer Trips

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Equipo SpaghettiViajarResiduos = Movimiento y Transporte

Resultados:

Pre: Celda: Mejora:Pasos totales: 857/ 10 8470% Astronmica !!Pies Distancia: 2571/ 30' 2541Menos ViajesCantidad de tiempo: 50 min / 15 seg Ahorros 49minViajes informticos: 12/ 2 88% menos viajes

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5S

5SWhat is it?Cleaner work areasMore organizationSafer working conditionsLess wasted timeEfficient work processes and practicesMore available space

Everything has a place and everything is in its place

SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN

5SQu es?Las reas de trabajo ms limpiasMs organizacinLas condiciones de trabajo ms segurasMenos tiempo perdidoProcesos y prcticas de trabajo eficientesMs espacio disponible

Todo tiene un lugar y todo est en su lugar

SORT, SET in ORDER, SHINE, STANDARDIZE, SUSTAIN

SORT, poner en orden, BRILLO, estandarizar, SUSTAIN

5SExample: Cell Set-up Shelves

After:

Before:

Teamwork Cell Start-up

Focused cell set-upCelular enfocada puesta a punto

More efficientMs eficiente

Clear instructionsInstrucciones claras

Checklist

QualityFirst Piece Verification

Calidad Primera Verificacin pieza

Focused on quality Form travels along with the first part during the build

Quality of the line is signed off before cell can proceed with production

Checklist

Centrado en la calidadForma transportar a lo largo con la primera parte durante la construccin

Calidad de la lnea se firm antes de celular puede proceder con la produccin

Lista de verificacin

First Piece Verification

Quality / Inspection must sign off completion

Triggers the start of production

Form will live in the cell during production

Cell DesignTeam focused on Pull over Batch processing

Studied One Piece Flow with a Paper Airplane Exercise.

Learned cell layouts and effectiveness

Created a U Shape cell as a team

Diseo de la clulaEquipo se centr en Tire sobre el procesamiento por lotes

Estudi "One Piece Flow" con un aeroplano de papel Ejercicio.

Diseos celulares aprendidas y eficacia

Creado una clula "U" en equipo

Cell Design

Cell Team Results:

Pre:Post: Improvement:Total Cycle Time:30min 12min MUCH FASTER !!FG Completed Takt:30min4min650% Improvement!!Quality:UnknownIn Line InspectBuilt in QualityLabor Time:96.9 hr act77.2 hr25% Labor SavingsDistance Feet:1845301815 Less TravelSpace / Foot print ft214400ft2216ft214,184 ft2 SavingsParts per hour: 215650% More per hourProduction Lead Time:3 weeks2 daysHappy Customers!

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Have Fun !!

The journey has just begun

to be continuedContinuously!

El viaje acaba de comenzar

continuarContinuamente!

Integrated Cable Systems

Cell Set-up / Start-up Protocol

CHECKLIST

|_|CLOCK IN / WORK ORDER

All operators / technicians must Clock on to appropriate process sequence

|_|VERIFY BUILD SHEETS: Rev level to Work Order Stations have copies posted

|_|TOOLING: All tooling is available and verified Dispersed to stations

|_|PARTS / COMPONENTS: Verify parts to the build sheets Collect any required pre-cut tubing

|_|LABELS: Distribute labels

|_|PROCESS STATIONS: Identify and tape WIP locations in the line Set-up all stations for production then every operator / technician must Verify incoming process for in-line inspection on every part

|_|NOTIFY QUALITY: Inform quality / inspection of cell start-up

|_|FIRST PIECE VERIFICATION: First process station operator / technician is responsible to: Initiate & Fill out top of form including Work Order ID / Assembly ID / Rev Level / Date Form will flow though the line with the first assembly part

ICS Form XXX - XXXX

Date: _________________________Integrated Cable SystemsAssembly Build Verification

First Piece VerificationWork Order IDAssembly IDRev Level

CHECKLIST Employee # InitIals

|_|PREP: Process complete per ICS build sheet Employee # Initials

|_|TERM: Crimp height measurement: ___________ Process complete per ICS build sheet Hand Tool # or Applicator #: ___________ Employee # Initials

|_|PLUG: Process complete per ICS build sheet Employee # Initials

|_|TIN: Process complete per ICS build sheet Employee # Initials

|_|SOLDER: Process complete per ICS build sheet Employee # Initials

|_|LABEL: Paste 1x ea below of every label on assembly. Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.

Attention: Paste on back of form if necessaryEmployee # Initials

|_|CLOSE: Process complete per ICS build sheet Employee # Initials

|_|TYWRAP: Process complete per ICS build sheet Employee # Initials

|_|COIL: Process complete per ICS build sheetEmployee # Initials

|_|WINDING: Process complete per ICS build sheet Employee # Initials

|_|___________________: Process complete per ICS build sheet Employee # Initials

|_|TEST: Process complete / Electronic Signature: ______________________________ Inspector # Initials

|_|FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per: customer print / specification / ICS build sheet Approved for continued manufacture Inspector # Initials

ICS Form XXX - XXXX

Date: _________________________Integrated Cable SystemsAssembly Build Verification

First Piece VerificationWork Order IDAssembly IDRev Level

CHECKLIST Employee # InitIals

|_|PREP: Process complete per ICS build sheet Employee # Initials

|_|TERM: Crimp height measurement: ___________ Process complete per ICS build sheet Hand Tool # or Applicator #: ___________ Employee # Initials

|_|PLUG: Process complete per ICS build sheet Employee # Initials

|_|TIN: Process complete per ICS build sheet Employee # Initials

|_|SOLDER: Process complete per ICS build sheet Employee # Initials

|_|LABEL: Paste 1x ea below of every label on assembly. Verify per print req. (Ref) (Assembly #, Rev), (Date Code), (Font size), (2x data), etc.

Attention: Paste on back of form if necessaryEmployee # Initials

|_|CLOSE: Process complete per ICS build sheet Employee # Initials

|_|TYWRAP: Process complete per ICS build sheet Employee # Initials

|_|COIL: Process complete per ICS build sheetEmployee # Initials

|_|WINDING: Process complete per ICS build sheet Employee # Initials

|_|___________________: Process complete per ICS build sheet Employee # Initials

|_|TEST: Process complete / Electronic Signature: ______________________________ Inspector # Initials

|_|FINAL VERIFY: First Piece Assembly/Sub-Assembly complete per: customer print / specification / ICS build sheet Approved for continued manufacture Inspector # Initials

ICS Form XXX - XXXX