OCG Chicago : Kaizen Event Small Turning (Mazak)

July , 2013 --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) --OCG Confidential--

Kaizen Event Team

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Kaizen Event Team

• Chris Boudreau – Event Sponsor • Nick Charbonnier – Team Leader • Terry Miller – Team Sub-Leader • Cesar Lopez – Team member • Rico Walton – Team member --OCG Confidential--

Lean Team Training

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Pre-project 5S Score: 1.25 S

Total Possible = 60 Points

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Pre-project state: Pic

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Mazak Current State

Unused rack, plastic hanging, improper outlet use, wires & hoses Storage on top of machines, tables have unneeded items, no labels, etc.

Bars & rods improperly stored and not labeled.

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Mazak Current State

Drill press not needed & parts missing label ID Unsafe table & unneeded items.

Various unnecessary items including skid of old jaws… --OCG Confidential--

RED Tagging: Remove unnecessary items

Out of service machine & jaws Drill press & unsafe table

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Kaizen Newspaper (Action list)

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Lean Team Hard at Work

Moving, Cleaning, Painting, Organizing

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Lean Team Hard at Work

Moving out obsolete equipment. Cleaning, Painting, racks & tables

Standardized BLUE color --OCG Confidential--

Improvements

Added Eye Wash station.

Changed 2-socket outlet to 4-socket to eliminate improper adapters Cleaned machine, drilled hole in cover and replaced onto machine.

Replaced air hoses running on floor to hard piped air supply and coil hose.

Fixed loose machine gages and hanging cover.

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More improvements

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 Moved machine created raw material staging area and cleared walking aisles. --OCG Confidential--

More improvements

Painted walls & posts according to OCG standard, labeled shelving and repaired water hose reel.

Non-Conforming part box More Labels Added Fire Extinguisher Safety stripping Cleared walking aisles. --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.

NVA Time: 36, 48, 44, 53 --> Avg. = 45 Seconds

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Pre-project state: Pic

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Post-project state: Pic

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Post-project 5S Score: 3.42 S

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Sustain: Daily 5S Checklist

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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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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.) --OCG Confidential--

Special Thanks to:

• • • • • • Danny Lyons Dennis Koukounaras Stanley Konopka Pete Rygula Miguel (Papo) Cortes Jose Dominguez • And anybody else we forgot.  --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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