5S Grinding Room Pressweld Value Stream

Transcription

1 Page 1 5S Grinding Room Pressweld Value Stream to

2 Scope Sheet Kaizen Event Scope / Sustainment Sheet Basic Data Kaizen Team Information Kaizen Event Name 5S Event - Inside Grinding Room Champion Jim Campisi Process Boundary Scope Inside Grinding Room Process Owner Primary Facilitator Cal Clark Tony Drenik Primary Lean Tool Used 5S Secondary Facilitator None Event Location (Facility) Watteredge - Avon Lake Team Leader (s) Chet Hollingshead Event Location (Room) Lunch Room Cal Clark Kaizen Event Dates to Terry Daugherty Daily Start Time 6:00 AM Jeff Roussin Kick Off Meeting Time 8:00 AM Tyler Moates Team Leaders Meeting Dates 11-29,11-30 and Team Members Erika Bentley Team Leaders Meeting Time 4:00 PM Darlene McIE Team Leaders Meeting Place Lunch Room Chet Hollingshead David Pullins Tony Drenik Report Out Meeting Date Report Out Meeting Time 11:00 AM Report Out Meeting Room Lunch Room Team Resources Maintenance Purchasing - Supplies Problem Statement (Must show relationship to KPI, VSM, Strategic Plan) Connected to Pressweld VSM Need to create sustainable processes around keeping the grinding area clean, neat and organized to help maximize efficiency within the department. Kaizen Objective (Must show relationship to KPI, VSM, Strategic Plan) Create a sustainable process around Sort, Set in Order, Shine, Standardize and Sustain in the Grinding Room. When done all equipment and items in area should be in like new condition. Page 2 Prework Data Collection Needed Cal - order long lead time parts needed to get equipment in like new condition Tony - take pre kaizen pictures of room and equipment

3 Day 1:Training Lean Overview What is Lean all about? Kaizen 5S What is this formal process? What is this LE Tool? Safety and Waste Analysis A process allowing us to SEE all of the waste around us!!! Page 3

4 Day 1 Training - Why 5S? Gives us a process to clean and organize the area followed by a process to maintain it Drives Safety Improves Quality, Delivery and Productivity Reduces Inventory Required for Visual Management 5S Sustain Sort, Straighten and Shine can be done in parallel but cannot be maintained without Standardize and Sustain 1S Sort 4S Standardize 2S Straighten 3S Shine Page 4

5 Page 5 Day 2 - Sort Break out into teams and Go Do It!!! Sort thru everything and remove unneeded items use the red tag system to discard items

6 Page 6 Red Tag Log Tag # VS Cell / Area Description Reason Date Disposition Date 57 PW Grinding Cart Not Used 28-Nov 14-Dec 56 PW Grinding Booth grating To Be Replaced 28-Nov 14-Dec 55 PW Grinding Booth grating To Be Replaced 28-Nov 14-Dec 47 PW OG Yellow Haz Mat drum container Not Used 28-Nov 14-Dec 50 PW Grinding Plastic containers Not Used 28-Nov 14-Dec 49 PW Grinding Form Not Used 28-Nov 14-Dec 51 PW Grinding Belt Sander Not Used 28-Nov 14-Dec 52 PW Grinding Misc. Not Used 28-Nov 14-Dec 53 PW Grinding Dolly Not Used 28-Nov 14-Dec 54 PW Grinding Roller Section Not Used 28-Nov 14-Dec 59 PW Grinding Deionized water Not Used 28-Nov 14-Dec

7 Page 7 Day 3 Straighten

8 Page 8 Day 4 - Shine

9 Page 9 Before and After Pics Before After

10 Page 10 Before and After Pics Before After

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22 Significant Improvements Replaced ceiling tiles Replaced light covers Added 6 lights Painted walls Replaced plastic doorway safety strips Repaired holes in the walls and floors Painted floor Cleaned and painted dust tables Replaced table grates Designated locations in each booth for tools and supplies 5S cleaning supply shadowboard installed Page 22

23 Page 23 Kaizen Newspaper Kaizen Newspaper Kaizen Name: 5S Pressweld outside grinding and machining area Team Leader: Cal Clark Kaizen End Date: 11/29/12 Step # Action Step Owner Assist Start Date End Date Current Status 1 Electric Panel - Trace and ID Breakers Subash Cal 12/7/12 12/14/12 2 Tools needed for all booths Cal Tony 12/1/12 1/1/13 On order due in Jan. 3 Install hooks for all tools in all booths Dave Cal 12/3/12 12/5/12 In process of being made in house 4 Stencil number on each booth and the booths tools Erica/Darlene Cal 12/4/12 12/5/12 5 Organize Red Tag area Snake Tony 12/4/12 12/5/12 6 Complete 5S Supplies Shadow Board Terry Tony 12/4/12 12/5/12 Supplies on order

24 Page 24 Sustainment Daily 5S Task List Operator Task Clean booth - only tools and supplies on table Sweep floor Clean off saw Wash booth down top to bottom Clean top of cabinets Wipe down carts, tables, buffer and grinders Organize cabinet contents Empty trash cans Mop floor Return cleaning supplies to 5S shadow board Shift Location # Monday Tuesday Wednesday Thursday 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd

25 Lessons Learned Need to remain flexible when the kaizen event is taking place. There will be items that come up that will need to be addressed that are not planned for and we will need to react quickly. Schedule events Wed Tue to allow floor paint drying time over the weekend. Communicate with department supervisors as new opportunities arise Page 25

26 Page 26 Next Up Next 5S Kaizen will be in the pressweld area of the department.