A3 Report Out Kitting Project June 1, 2009
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Exercise Lean LLC Prepared by John Petak 864.363.0984 Implementation/Action Plan A3 Project Summary Background / Business Case : Initial Condition : Project Leader: John F. Petak Team Members: Mike Campbell, Laura Carden Frederick Cosby Project Name : Trust Technologies , Inc. Warehouse Kitting Project Indicators/Measurables : Future Condition : Trust Technologies currently supplies Woodward FST 4 parts on daily pull system. We would like to delivery in 7 kits 37 part references from on site warehouse to include 5 other supplies to Woodard FST. This would generate savings for Woodard FST on floor space, inventory reduction, manpower utilization, potential freight costs. C urrentState Future State Target Target Savings A ctual Savings % Change Floor Space 200 sq ft 350 sq ft 3.4% People 2 2 2.0 Freight TBD TBD Inventory 12 units 12 units - Jan Feb M arch April M ay June July A ug S ept O ct N ov D ec 1. J.P etak 4 hrs G reen 2. J.P etak,F C osby 2 hrs G reen 3. J.P etak .5 hrs G reen 4. J.P etak 2 hrs 5. J.P etak 2 hrs G reen 6. J.P etak 2 hrs G reen 7. J.P etak 4 hrs G reen 8. J.P etak,C M anley 9. J.P etak,C M anley 10. J.P etak,C M anley 11. J.P etak,C M anley 12. J.P etak,C M anley 13. J.P etak,C M anley 14. J.P etak,C M anley 15. J.P etak 16. J.P etak 17 J.P etak 18 J.P etak 19 J.P etak 20 RFQ P rinter& S cannerforhandling paperw ork J.P etak,R S tudart 21 Total - $ 0 0 TotalS tatus Prepared by: Planned StartDate A ctual StartDate Status: E xercise Lean LLC -John P etak Finish Date Finish Date G reenTargetA chieved C oncept,D esign,P rocure,Test,V alidate,S tartP roduction M ilestone Com pleted M ilestones Y ellow Targetin Jeopardy Duration Period Duration Period Red TargetM issed No P roject S ingle A ctions E xplanation ofC urrent S tatus O n tim e delivery Actual R esults($) O thertargets: M easurable Targets: W alk W oodw ard FS T value stream s S tatus O w ner C oncept.define 7 kits forflow lanes footprint Im plementation Expense ($) B uild w orksheetP FE P V alue stream m ap currentstate 4 Trustparts VSM W oodw ard FS T com ponents C onceptdesign kitforS w ozzle 601P 065-01 Tim e S chedule 2009 C oncept,design kitforA ssem bly -A ssy S w irlerA dpate 601P 054-01 C reatfuture state V S M forkiting proposes C oncept,design kitforS hroud -W eld assy IFC 601P 554-01 Target R esults ($) C oncept,design kitforA ssem bly-W eld P rem ix Tip Tub 601P 058-01 C onceptdesign kitforFlange 520P 451-01,02 TrustTechnologies,Inc -G reenville,S C K itting C om ponents -W FST & Trust Trustto W ooodw ard FS T John F. P etak W e currently supply 4 parts to W oodw ard FST on daily basis.They are Flange 520P451-01,02;S wozzle 601P065-01,; Fuel Tip A sem bly 520P 464-01 thru 12;Fuel Tip Assem bly 520P 750-01 and w e w ould like to expand this to central "pick" w arehouse system which w ould include 33 partreferences from W FST and 4 from TrustTechnologies,Inc. B usiness U nit/Facility: V alue S tream : V alue S tream Loop: V alue S tream O wner: C onceptdesign kitforFuelTip A ssem bly 520P 464-01 thru 12 C onceptdesign kitforFuelTip A ssem bly 520P 750 -01 RFQ forfoam inserts for7 kits /C arts C oncept,design layoutforkiting C oncept,design kitforR ing-B razing 506P 399-65 C oncept,design kitforA ssem bly-W eld O uterB ellow s 601P 055-01 C oncept,design kitforA ssem bly 601P 056-01 C oncept,design kitforA ssem bly -W eld D iffTip Tube 601P 057-01 0 0 0 0 0 1 1 1 1 1 1 previous year Feb A pril June A ug O ct D ec P rojectM etric
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Transcript of A3 Report Out Kitting Project June 1, 2009
Exercise Lean LLCPrepared by John Petak864.363.0984
Implementation/Action Plan
A3 Project Summary
Background / Business Case:
Initial Condition:
Project Leader: John F. Petak
Team Members: Mike Campbell, Laura CardenFrederick Cosby
Project Name: Trust Technologies , Inc. Warehouse Kitting Project
Indicators/Measurables:Future Condition:
Trust Technologies currently supplies Woodward FST 4 parts on daily pull system. We would like to delivery in 7 kits 37 part references from on site warehouse to include 5 other supplies to Woodard FST. This would generate savings for Woodard FST on floor space, inventory reduction, manpower utilization, potential freight costs.
Current State Future State Target Target Savings
Actual Savings
% Change
Floor Space 200 sq ft 350 sq ft 3.4%
People 2 2 2.0 Freight TBD TBD
Inventory 12 units 12 units
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Jan Feb March April May June July Aug Sept Oct Nov Dec
1. J. Petak 4 hrs Green
2. J. Petak, F Cosby 2 hrs Green
3. J. Petak .5 hrs Green
4. J.Petak 2 hrs
5. J.Petak 2 hrs Green
6. J. Petak 2 hrs Green
7. J.Petak 4 hrs Green
8. J.Petak, C Manley
9. J.Petak, C Manley
10. J.Petak, C Manley
11. J.Petak, C Manley
12. J.Petak, C Manley
13. J.Petak, C Manley
14. J.Petak, C Manley
15. J. Petak
16. J. Petak
17 J.Petak
18 J. Petak
19 J. Petak
20 RFQ Printer & Scanner for handling paper work J.Petak, R Studart
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Total -$ 0 0 Total Status
Prepared by: Planned Start Date Actual Start Date Status:
Exercise Lean LLC - John Petak Finish Date Finish Date GreenTarget Achieved
Concept, Design, Procure, Test , Validate, Start Production Milestone Completed MilestonesYellow Target in Jeopardy
Duration Period Duration Period Red Target Missed
No Project Single Actions
Explanation of Current Status
On time delivery
Actual Results($)
Other targets:Measurable Targets:
Walk Woodward FST value streams
StatusOwner
Concept. define 7 kits for flow lanes footprint
Implementation Expense ($)
Build worksheet PFEP
Value stream map current state 4 Trust parts
VSM Woodward FST components
Concept design kit for Swozzle 601P065-01
Time Schedule 2009
Concept, design kit for Assembly - Assy Swirler Adpate 601P054-01
Creat future state VSM for kiting proposes
Concept, design kit for Shroud - Weld assy IFC 601P554-01
Target Results ($)
Concept, design kit for Assembly- Weld Premix Tip Tub 601P058-01
Concept design kit for Flange 520P451-01,02
Trust Technologies, Inc - Greenville, SCKitting Components - WFST & TrustTrust to Wooodward FSTJohn F. Petak
We currently supply 4 parts to Woodward FST on daily basis. They are Flange 520P451- 01,02; Swozzle 601P065-01, ; Fuel Tip Asembly 520P464-01 thru 12; Fuel Tip Assembly 520P750-01 and we would like to expand this to central "pick" warehouse system which would include 33 part references from WFST and 4 from Trust Technologies,Inc.
Business Unit/Facility:Value Stream:Value Stream Loop:Value Stream Owner:
Concept design kit for Fuel Tip Assembly 520P464-01 thru 12
Concept design kit for Fuel Tip Assembly 520P750 - 01
RFQ for foam inserts for 7 kits / Carts
Concept, design layout for kiting
Concept, design kit for Ring- Brazing 506P399-65
Concept, design kit for Assembly- Weld Outer Bellows 601P055-01
Concept, design kit for Assembly 601P056-01
Concept, design kit for Assembly - Weld Diff Tip Tube 601P057-01
00000111111
previous year
Feb April June Aug Oct Dec
Project Metric
Exercise Lean LLCPrepared by John Petak864.363.0984
Storage LocationParts @ CleanParts @ Process Parts @ Pick
Point of Use Dock Door
601P054601P055601P056601P057601P058
601P054601P055601P056601P057601P058
601P054601P055601P056601P057601P058
601P054601P055601P056601P057601P058
Supervisor
Warehouse
Shipping &
receiving
Production
Planner
EPE DailyPeople 2OHI 12Floor Sp 48sq ft
EPE DailyPeople 2OHI 12Floor Sp 6 sq ft
EPE DailyPeople 2OHI 12Floor Sp 45 sq ft
EPE DailyPeople 2OHI 12Floor Sp 0
Picker Picker
Work orders 601P057
Move to kitting area
Direct Ship
castings
Direct Ship all
Components
Current State Woodward FST
June 1, 2009
Current State – Woodward FST
Exercise Lean LLCPrepared by John Petak864.363.0984
Woodward FST
Current State – Trust Technologies, IncWoodward FST
Woodard FST
Accurate Brazing
EMJ
Aerodyne
520P451-01,02
540”
630”36
Daily
520750-01
25’
Daily36
6 hrs
520P464-01,12
2,215”
0
Daily
36
601P065
Daily
368 hrs
2,688”
Forecast 6-8 wks
E mails, phone calls
E mails, phone calls
Fork Truck
540 sec 2,215 sec 25 min 2,688 sec
3 days 1 day 2 days 3 days
VSM – Kitting Project
Current State Map
Daily
520P451,01,02
630”
540’
36
Daily
Exercise Lean LLCPrepared by John Petak864.363.0984
36parts /day
601P054-01
36parts /day
601P052-01
36parts /day
601P056-01
36parts /day
601P055-01
36parts /day
601P554-01
36parts /day
601P057-01
36parts /day
601P058-01
520P452-01
601P062-01
520P464-01
601P061-01
601P060-01
520P459-01
116E4680P001
601P065-01
601P053-01
601P064-01
#1KIT
#7KIT
#6KIT
#5KIT
#4KIT
#2KIT
#3KIT
601P063-01
520P581-01
601P059-01
520P464-01
520P750-01
520P578-01
520P578-02
520P577-01
520P580-01
520P579-01
520P451-01
506P405-87
506P406-26
506P408-26
506P407-97
506P409-51
506P406-40
506P399-65
506P400-03
520P467-01
520P468-01
520P862-88
522P014-01
Phone CallsPrinter/ScannerE-mails
Phone CallsE-businessE-mails Woodward
Trust
Future State – Trust Technologies, Inc.
Fork Truck Deliverydaily milk runs
Meetings
Meetings
Kitting Associate
Target = Pull & pick 1 kit every 1.5 hrs
Exercise Lean LLCPrepared by John Petak864.363.0984
Exercise Lean LLCPrepared by John Petak864.363.0984
