C O N S U L T I N G

Kaizen Event Final ReportARTURO BOLAÑOS, L EAN COACH & S I X S I GMA BLACK BELT

Why are we implementing Operational Excellence?

Expectations from Participants

Before Pictures

Current State of Assembly Shop

What do you see?

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Current State Floor Layout with Spaghetti Diagram

16' 6" x 25' 0" 16' 6" x 25' 0"

Room

16' 6" x 25' 0"

Room

16' 6" x 25' 0" 16' 6" x 25' 0"

Room

8' 9.5" x 25' 0"

Room

3' 0.25" x 25' 0"

Computer Workstation

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WIP

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Build ROCWork Table

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Inve

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Back Panels Tool Box

Inventory Rack

Wiring Panel & Install ROC

Work Table

#1

#2

#3a

#4

Tool Box

Back Panels Inventory Rack#4aFerral Process

Work Table

#3

Wiring Panel & Install ROC

Work Table

Wiring Panel & Install ROC

Work Table

#5#5

#5

#5a

Wiring Panel & Install ROC

Work Table

Tool Box

#5

#5a

#6

Wire RackInventory Cabinets

Inventory Cabinets

Inventory

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Tool BoxBack

PanelsBack

Panels

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Inventory Inventory

InventoryInventory E

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Pcs

Find the problem areas and the metrics before the Kaizen event.

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Before Metrics

KAIZEN EVENT GOALSIMPROVEMENT METRICS BEFORE KAIZEN GOALS FOR KAIZEN

Cycle (Build ) Time 14.8 Hrs. 10.0 Hrs.

% Complete Rate 90.0%* Over 95%

Travel Distance 4162 feet 75% Reduction

Safety Issues 2 0

5S Score - Percent 30% 80%

Find the problem areas and the metrics before the Kaizen event.

*Three month average from Aug, Sept and October

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Takt Time Calculation

Customer Demand 64 units per monthCustomer Demand 16 units per weekCustomer Demand 3.2 units per day

Available Time 8 Hour shift 480 minutes start endBreaks 30 minutes 7:00 AM 16:00Clean up 10 minutesCalculated 8 hours 440 minutes

Takt Time Available Time/Customer DemandCalculated Takt Time 137 minutes

Calculated Customer Demand from previous three months data.

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Current State with 8 Hours Shift

The calculation reflect a 2 ½ week study of the Line. The Pan Assembly and Wire Panel/ ROC are the constraints with a total cycle time of 14.8 hours.

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Cut Wire BuildHarness

FerrelProcess

PanAssembly

Build ROC WirePanel/Install

ROC

QualityCheck

IntegratePanel

EOL Tester Pack

Line BalancingCurrent State

Cycle Time Takt Time

137 Minutes

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Current Metric

Monthly Completion

74.3

3 month Completion Rate Sept, Oct, Nov.

74.6 90

121.3

The Graph to the left is the data collected from weekly Completion Rate per panel. We collected data from Sept to October and took an average.

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Training Pictures

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Brainstorming The Brain Storming with 3M Post it's a tool used to sort through the brainstorm ideas from the team.

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Value GraphThe Value Graph is a tool used to sort through the brainstorm ideas from the team.

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Implementation PlanAn implementation plan is a plan put into affect to make a change. It is a detailed project that outlines any changes made and explains how the changes will come about.

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During Kaizen

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During Kaizen

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Future State Floor Layout with Spaghetti Diagram

16' 6" x 25' 0"

16' 6" x 25' 0"

Room

16' 6" x 25' 0"

Room

16' 6" x 25' 0" 16' 6" x 25' 0"

Room

8' 9.5" x 25' 0"

Room

3' 0.25" x 25' 0"

Computer Workstation

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Wir

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ack

sKITS, Built ROC, Prewired

Tool Box

Wire Harness Inventory Rack

Pan Assembly

Tool Box

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it, P

an

Ra

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Wiring Panel & Install ROC

Work Table Quality Check

Wire Rack

Computer

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Wire Assembly Work Table

Hardware Cabinet

Misc Ribbons Cabinent

Pan Assembly

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Daniel’sTool Box

ClaudiaTool Box

Don’s Tool Box

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#4 #5

EOL tester

#9Finish Goods

Finished Goods

Finish Goods

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Build & Wire ROCWork Table

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Wiring Panel & Install ROC

Work Table #4

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Wire & I/O Assembly

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Wire Racks

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One -Off

Wire & I/O Assembly

Work Table

Asset Team Area

Connoco/Marathon Line#1

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Future State with 8 Hours Shift

The calculation reflect with a Relayout of the line and deploying the employees to the bottlenecks to reduce the total cycle time to 9.2 hours.

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Wire Harness Build ROC Pan Assembly WirePanel/Install

ROC

Quality Check Integrate Panel EOL Tester Pack

Relayout Line BalanceFuture State

Cycle Time Takt Time

137 Minutes

Combined three operations to make

one.

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104.5111

89

119

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Wire Harness Build ROC Pan Assembly WirePanel/Install

ROC

Quality Check Integrate Panel EOL Tester Pack

Relayout Line BalanceFuture State

Cycle Time Cycle Time Takt Time

137 Minutes

Future State with 8 Hours Shift

Further improvements on the line to reduce bottleneck in the Pan Assembly and Wire Panel/Install ROC to total cycle time of 8.3 hours

Reduction of 48 minutes from

process Additional Savings of 23 minutes by

moving wire harness to Wire

Harness Area

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After Pictures

A vision of how our line may look after the Kaizen Event

What do you see?

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Follow-up ActionsProposed Kaizen Event

When Target Date Responsibility Completed

Verify 5S Visual Management Board is installed One week after event 12/18/2009 Team Leader Open

Verify the Pre-Kaizen 5S Audit has been posted One week after event 12/18/2009 Kaizen Leader Audit Completed

Verify the Cleaning Plans have been posted. One week after event 12/18/2009 Team Leader Completed

Perform 5S Audit using Checklist Two Weeks After 1/14/2010 Kaizen Leader Completed

Standard Work for RAS Line Two Weeks After 1/14/2010 Kaizen Leader Completed

Traing supervisor on cleaning plan Two Weeks After 1/14/2010 Kaizen Leader Completed Buy 3 Level 2 x 6 foot shelve for built ROC

Two Weeks After 1/14/2010 Scott Nicely CompletedAssemble 3 Level 2 x 6 foot shelve for built ROC

Two Weeks After 1/14/2010 Dean CompletedComputer to make tags or lables for wire harness Two Weeks After 1/14/2010 Scott Nicely Completed

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After Metrics or results

The Graph to the left is the data collected from weekly Completion Rate per panel. We collected data from Sept through 3rd Week of January.

Kaizen Events were held on Dec 12 & 22 and affected the completion rate. The line started Stress Testing the of WK 1/23.

74.3 74.6

121.3

71.8

97.8

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Monthly Completion Completion

Weekly/Monthly RAS ShopCompletion Rate Delivery

Perc

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For the month of January the average completion rate is 97.8%. Exceeding the 95% of monthly goal.

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After Metrics or results

KAIZEN EVENT GOALSIMPROVEMENT METRICS

BEFORE KAIZEN

GOALS FOR KAIZEN AFTER KAIZEN

% IMPROVEMENT

Cycle (Build ) Time 14.8 hrs. 10 Hrs. 9.2 37.8%Completion Rate per month (%) 90%* 95% 97.8%** 7%

Walking Distance 4162 feet 50% reduction 114 feet 97.2%

Safety Issues 2 0 0***

5S Score - Percent 30% 80% 66% 62.5%

*Three month average from Aug, Sept and October.

** Monthly average from Jan 2010.

*** Safety issue eliminate using A-Frame.

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Kaizen Team

The picture of the entire Kaizen Team that participated in the two Kaizen Event. Starting in the back row right is Daniel Enriquez, Felix Hughes, Carlos Silva, Becky Taylor, Don Clark, and Alex Trujio. Starting the front row begins with Dean Holmes, Patricia Stevenson, Claudia Riojas, Tim Potter, and Kaizen Instructor Arturo Bolanos.

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A proven results oriented bilingual leader with manufacturing and transactional experience. Lead the development, implementation and performance of a process improvement system for companies in Oil & Gas, Power Generation, Automotive Electronics, Semiconductor, Medical Device, and Hot Spas.

Specialties: • Provide LEAN and Six Sigma Training to Senior Management and Supervisors.• Lead, executed, tracked and report high impact projects using, PDCA

methodologies.• Deliver formal training in Six Sigma, LEAN, and Continuous Improvement

methodologies.• Coordinate with Process Owners in development of Value Stream Maps and

Process Mapping.• Provide Project Management for LEAN and Six Sigma projects.• Deliver Kaizen Leader and LEAN Facilitator Training throughout US, UK, &

Switzerland.• Lead, coached and mentor in Lean & Kaizen Events within Manufacturing and

Service settings.

What I can do for your organization.

2/11/2013 – v6.0

Over 5.8 million dollars of cost savings in LEAN and Six Sigma Projects through out career.

Trained led, coached and mentored over 75 Kaizens from 5S to Relayed Lines.

Delivered projects with over 50% of lead-time reductions on LEAN Events.

Improved On-time Delivery from 45% to 90% at Proserv Facility.

Delivered projects with over 30% of transportation reductions on Kaizen Events.

Led two companies to successful QS-9000 certifications.

Managed cross-functional teams to 17 successful Production Part Approval Process (PPAP).

Accomplishments

2/11/2013 – v6.0

Thank you for viewing my presentation

If you enjoyed the presentation or have questions, please contact me at arturofbolanos@gmail.com or call me at 832-486-0159. I am available to consult with your company or open to new opportunities.

Best regards,

Art Bolanos

2/11/2013 – v6.0