Reducing Bottling Lines Downtime at

LeVecke Corporation Ismael Reyes

SGB 110 -2016

Define-Project Charter

Define- SIPOC S I P O C

• Tank Room• Receiving Department• Shipping Department

• Liquid/Product• Dry Components• Pallets

• Finished Case Goods• Pallets

• Warehouse• Shipping Department

Request for Components Rotate

Request for QC Check

Bottle Accordingly

to PlanClean

• Repeat as necessary depending on production schedule

Measure

Palletize

r

MIS ALIGNED LA

BELS

BROKEN Bottles

Clean Table

BOTTLE CODER

DUMPER

Clean Sleeves

Wait for M

aterial

Low Fill

Air Compresso

r Down

Broken Bottles i

n Capper

Change Sleeves

Sleeve Stop

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0

2

4

6

8

10

12

14

2.60

1.68

0.880.78

0.420.32

0.00 0.00 0.00 0.00 0.00 0.00 0.00

11

7

13

4

12

01

0 0 0 0 0

MARCH OTHER LINE STOP 2016

HOUR FREQUENCY

HOUR

S

FREQ

UENC

Y

YTD Loss: $ 3,400Downtime: 11 Hours

Measure

Line D Line G

Measure-Stocking Palletizer Flowchart

Analyze-Cause and Effect Diagram

• Irregular Size Pallets• Protruding Nails

• Chains and Sprockets and Gears not Covered

• Old Equipment • No TPM

• No Pallet Inspection Process • No Specific Directions to

Vendor

• Forklift Operator Not Trained Properly

Analyze

0

10

20

30

40

50

60

70

80

72

60

44

2421

8 6

Palletizer Down Reasons

PHOTO EYE JAM PALLETS WOULD NOT EJECT LINE DOWN ROLLERSWRAPPER CASES FELL ACTUAL PALLET CAUSING ISSUE

Reason

Min

utes

Improve• Remind Pallet Supplier Regarding Our Grade A Pallet Requirement• Possible Chargebacks If Not Compliant

• Properly Trained Forklift Operator • He Has To Inspect Pallets Before Stocking • He Knows What Is Conforming and Nonconforming

Improve-Stocking Palletizer Flow Chart

Improve

Improve

1 2 3 4 5 6 7 8 9 10 11 120

10

20

30

40

50

60

Run Chart

MINUTES AVG

Min

utes

Control

Control March April