Kaizen Blitz: AR Room SMED Processes

Sally Ulman & Alan Magner

Mon-Wed 24th – 26th October, 2015

Contact:alanmagner@variancereduction.com

Agenda (see detailed agendas for each team)

MondayLean overview

Measure current state

Develop Action Item List

TuesdayComplete Action Item List, new process map - Morning

Map new process, document improvements, SOPs – Afternoon

WednesdayConduct new Change over - Morning

Develop Presentation, Make Presentation @ 4pm

Leadership Support

We empower the team to make process improvements

Major changes will be reviewed and approved when possible

Time, resources and equipment will be provided

We hope most changes will occur DURING the event, all other action items will be given time to complete in the future

Kaizen Blitz Vision

Faster, Better, We Help People See.

Our aim for 2005 is to consistently deliver 48hr service to our Retail Customers from time of order to delivery back to store.

Scope of Activity

3 - Day Kaizen Event focusing on AR Changeover to:

Changeover time reduction

Increased machine productivity, run time

Improve cell organization

Improve ergonomics & safety

Clear SOPs & training materials

AR Setup Reduction Kaizen TeamTeam “C.S.I.”Clean Syrus Improvement

Team Members

David Fairclough

Ed Soriaga

George Webster

Facilitator:

Alan Magner

No. of operstors to do the task

Skill level of operators

Level on Cleanliness (scale 1 - 5)

Amount of shields to change

humidity in the room

Machine Run time

Sandblast machine - pressure

Sandblast machine - quality of beads

Machine downtime

scotchbrite pads, chux wipes

Product mix (ultra Vs Invisibles)

Ease to clean (scale 1 - 5)

sequence of shield changes

Frequency of cleaning

The INPUTS can be found by considering the 6 M's:

Manpower Methods

Machines Measurement

Mother Nature Materials

INPUTS OUTPUTS

Shield

cleaning

on Syrus

Process IPO – Syrus Clean

SMED Process

Observe cleaning process, record times

Eliminate wasted / unneeded steps

Remove duplication of tasks

Move steps from Internal to External of the set-

up

Simplify steps

Improve safety at every opportunity

Action Item List

Amount of actions listed 28

Actions taken 20

Actions outstanding 8

Completion Rate 71%

Phase 1 - Eliminate waste

Breakdown of Phase 1 improvement

Int. Time

57%

Ext. Time

2%

Eliminate

41%

Total Time: 2h 30m 9s

Time to

eliminate:

1h 2m 18s

Steps made external to set-

up:

3m 45s

Steps staying

internal to

set-up:

1h 24m 6s

43% reduction

in set-up time

Breakdown of Phase 2 improvement - 2 people

Total Internal Time

38%

Time reduction with 2nd

person

18%

External Time

2%

Eliminate

42%

Phase 2 - Add 2nd personTotal Time: 2h 30m 9s

Time to

eliminate:

1h 2m 18s

Steps made external to set-up: 3m 45s

Steps staying

internal to

set-up:

57m 32s

62% reduction

in set-up time2nd Person:

26m 34s

Breakdown of Phase 3 Improvement - 2 people, spare shields

Total Internal Time

32%

Time reduction with 2nd

person

24%

External Time

2%

Eliminate

42%

Phase 3 - Have extra shieldsTotal Time: 2h 30m 9s

Time to

eliminate:

1h 2m 18s

Steps made external to set-

up:

3m 45s

Steps staying

internal to

set-up:

47m 22s

68% reduction

in set-up time2nd Person:

36m 44s

5S - Shield TrolleyShields were stacked on top

of each other

Before After

Every shield has a place

5S - Shield TrolleyBefore After

Visual Control: Preparation Checklist

Have we everything we need? - easy to see

Sandblast machine

Sandblast machine

Trolley

Trolley Trolley for

clean parts

Trolley for dirty

parts

Dirty

parts

in

Clean parts out

Layout - Sandblast roomBefore - no clear workflow After - dedicated workflow

Safety improvementHard to reach the V-1 -

hazardBefore After

Safe access - using ladder

Standing on/in machine

parts to accomplish

cleaning task

Ladder now creates a safe

work platform and no

damage to machine parts

Error ProofingBest angle for safe cleaning

& preventing machine damage

Visual - not locked in place

Error ProofingCover to prevent damage to filament during cleaning

Photo-rich SOPs

Visual Controls

•Each part stamped with a

unique identifier number

•Each number is also the

sequence number for

inserting the shields

Making the changes

Track & SustainMinute for Syrus Clean

162

150

44

0

20

40

60

80

100

120

140

160

180

6-Oct 11-Oct 26-Oct 31-Oct 5-Nov 10-Nov 15-Nov 20-Nov 25-Nov 30-Nov 5-Dec

Min

ute

s

Minute to clean Goal (60 mins) Stretch Goal (45 mins)

1st attempt at new

procedure: 43m 40s

Set-Up Results

Set-Up Times for Syrus Clean

2:30:09

1:24:06

0:57:32

0:47:22

0:00:00

0:30:00

1:00:00

1:30:00

2:00:00

2:30:00

3:00:00

Before Kaizen Removing

Wasted Steps

2 People Extra Shields

}Saved

1h 42m 47s

per clean

68%

reduction

$$ SavingsAR Room :

•2 Syrus coaters

•Each are cleaned 6 times / month

•Cleans / Year = 144 times

•Hourly revenue = $900

(160 lenses @ 40mins)

•Revenue = $15 per minute of downtime

•Opportunity, every minute reduction in cleaning time results

in an annual saving of $2160 per minute

$$ Savings

Saved

1h 6m 3s

per clean

44%reduction

Phase 1

Improvements :

•eliminated waste and

unnecessary steps

$142,560 p.a.

Saved

1h 32m 37s

per clean

62%reduction

Phase 2

Improvements :

•Have 2 people do

clean together

$198,720 p.a.

$$ Savings

Saved

1h 42m 47s

per clean

68%

reduction

Phase 3 Improvements :

•Extra shields & parts

$220,320 p.a.