THE UNIVERSITY OF TEXAS ARLINGTON

INTERNSHIP REPORT IE 5191

Lean Manufacturing and Maintenance Operations Internship-IE 5191

SHRIRAAM MADANAGOPAL100587483

INDUSTRIAL ENGINEERING12/2/2009

Fall 2009, Lean Manufacturing and Maintenance Internship, Stanley Tools-Stanley works Dallas TX

SUBMITTED: DR.JOHN PRIEST

IE 5191-001- Maintenance Operations Internship, Fall 2009

Stanley Tools, Dallas TX

Introduction:

Stanley tools:

Stanley® Proto® is a global leader in the industrial tool industry, selling tools under the names Proto®, Facom®, Blackhawk™ and Stanley®.

Proto® Tools are preferred worldwide among professionals for their outstanding quality, durability, and dependability. They are used for heavy-duty industrial applications, including auto-manufacturing plants, steel and airplane manufacturing, chemical plants, refineries, general manufacturing, transportation, and fleet maintenance for trucking, transit, and aircraft. With a global distribution network, Proto® Tools are available on-the-job, anywhere in the world.

Stanley branded industrial tools are the most durable professional industrial tools available. Their superior design and advanced product features reflect the direct knowledge and experience of professionals. Developed according to strict ergonomic standards, they offer special advantages such as enhanced shock absorption and reduced slip, as well as unique designs to ensure faster, easier work for the professional craftsman.

Maintenance Operations Intern:

As a Maintenance Engineer for the manufacturing plant of Stanley Tools Dallas, TX- I had to perform the following duties.

Application of various concepts of Maintenance Engineering for the optimization of Equipments, Manufacturing methodologies, safety engineering to achieve a better maintainability, reliability and availability of the equipments.

Monitored the equipment performance and safety to ensure that the equipment performs to the set standards safely and repairs are completed before breakdowns or unsafe conditions. The safety regulations and electrical compliance standards were well organized and inspected before the equipment performance using a time study analysis.

Performed and successfully implemented the preventive maintenance audits to make sure that there wasn’t enough variation and decrease in productivity rate for a given manufacturing operation.

The concept of Productivity was well understood when I practically implemented and suggested improvement standards for productivity.

Productivity:

The concept of Productivity has gained more importance with a practical exposure to the working environment. I can attribute productivity as a measurement, to evaluate the efficiency of production, considering the ratio of the output of the goods and services to the input factors of production.

Labor Productivity encompasses the inputs of the entire employee hours worked. Capital Productivity takes into account the inputs of machines and other resources used. Marginal Productivity measures the additional output gained from an additional unit of input. A Technique to improve productivity involves the usage of wider range of new technology, altered working practices and improved training of the workforce.

The Methods to incorporate successful Productivity improvements were:

Prioritizing maintenance tasks to ensure production orders are filled safely and on time Constant Monitoring and prioritizing the employees time, skills and training to ensure that employees time

is spent efficiently Monitored and prioritized maintenance spending so that repairs are made on time at the best value Developed and implemented cost savings measures to current production methods/ machines using Stanley

tools software Responsible for electrical compliance for the Black Hawk Manufacturing unit Maintained the current asset list Analysis of repetitive equipment failures over certain processes/time

The prime objective of performing a preventive maintenance is to avoid or mitigate the consequences of failure of equipment. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, I recorded equipment deterioration by letting my boss know when the next replacement or repair for the worn parts would occur before they caused any system failure.

Emphasis on Lean Manufacturing from the Internship and Classes from Industrial Engineering:

From the Production and Inventory Classes and Intern as a Maintenance Intern my understanding on lean manufacturing will be as follows:

Lean Manufacturing from an Industrial Engineer point of view will be a business operation which continuously reduces or shortens the time between customer order and shipment by eliminating everything that increases cost and time.

Carried out the following functionalities in the plant for achieving increased improvements from Lean Perspective:

Reduction of Inventory with respect to space and time

Reduction of Manufacturing time by devising idea of pick and place robot to perform multiple operations with precision, accuracy, repeatability thereby reducing labor cost and improved manufacturing time

Reduction of Materials wastes, recycling of scrap materials

Reduction of Machine Idle time, labor cost

Reduction of unwanted movement of materials and objects

The Lean Manufacturing techniques were established with the below mentioned protocol:

Data Collection Stage Data Analysis and development of solution stage

Implementation stage

The following flow chart explains the rest of the process.

Data Collection

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Data Analysis

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Implementation

Data Collection Stage:

Time studies and Motion studies Establishment or review of Process Flow charts Investigating Product families Bottle necks and problem areas

Data Analysis:

Establishment of a Capacity plan Determination of the current state of the Value Stream Map Value Stream Map Future state – Micro and Macro Levels Determining the Work Balance Design of a Layout proposal Preparation of a Project Implementation plan

This stage will have three documents as output:

Time and Motion Studies

Customer Demand

Process Flow Product Families

Capacity Plan Value Stream Map the current status

Value Stream Map Future Status

Work Balance Layout Proposal

Project Plan- Implementation

Evaluation Document comprehending analysis and calculation Design Document proposing a solution leading to a

Project implementation plan

Implementation:

Execution of the project implementation plan. Design and manufacture of special tools and material handling equipment

Outsourcing of Capex (if needed)

Training of relevant staff

Continuous Improvement Process:

Lead the Lean Manufacturing Strategy with input and support of the General Manager/ Engineering Manager/ Manufacturing Manager.

Implemented continuous improvement / lean manufacturing activities to support site strategies. Responsible for Process Control systems which included: Document Control, Continuous Improvement

identification and methods, Process Deviations/Change procedures, Auditing methods and accountabilities, new process/product introduction procedures, and appropriate document traceability.

Lead continuous improvement workshops as needed Manage Action Register and responsiveness to associate recommendations Held responsible for the Ownership of Value Stream maps and lead projects toward implementation of

Future State

As a Maintenance operations Intern, I had performed the functionalities which lead to the implementation of the various optimization techniques right from identifying the troubleshooting mechanisms to the root cause analysis of problems related to maintenance and lean manufacturing. Apart from the above mentioned functionalities, I worked

Documentation of the current state of facilities and operations

Documentation of Analysis, Evaluation and Calculation done

Documentation of Proposals

Documentation of the project implementation plan Guidelines for operation and Maintenance

to provide statistical quality auditing for Black Hawks produced per day. Usage of SAS was very useful to perform regression analysis chart for breakdowns. With this regression analysis variation from equipment to equipment were analyzed and suggested improvement actions which was taken and well appreciated by the management.

Roles played as Maintenance Operations Intern:

Responsible for maintenance and capital improvements of the plant facility Responsible for implementing and managing continuous improvement efforts/initiatives, lean

manufacturing efforts/initiatives, Six Sigma projects, R&A reduction efforts/initiatives, scrap reduction efforts/initiatives, process improvement/quality improvement efforts, Kaizen events, 3P events and 5S activities

Installation of equipment, start up, budget and schedule

Responsible to set up and implement preventive maintenance program for all new and existing equipment

Keep track record of applying strategic tactics and continuous improvements to minimize costs and maximize profitability

Leads equipment acceptance, check out, calibration and training activities for all new installations

Interaction with product, process and packaging staff to optimize process conditions and equipment settings to support development projects

Analysis of production data and product specifications to establish quality and reliability variable for finished products

Assisted in the preparation of Safety Report Assessment & Maintenance Procedures

Collected and analyzed internal data to improve production

Prioritized process, assigned work orders and assured completion

Research and recommend purchase of new equipment and materials

Managed installation, maintenance, and repair projects in electrical work, HVAC

Conducted troubleshooting, diagnosis, and repair of equipment; and assure preventive maintenance and proper replacement of equipment, parts and components

Got involved with methods and techniques used in general cleaning and maintenance activities

Assisted and supported coordination of facilities planning and construction

Reduced material handling activities through automated material handling systems and layout changes to improve throughput within the operation

Implemented cell manufacturing concept within the cold heading operation thereby reducing the work-in-process inventory and elimination of non-value added material movement

Assisted in managing the maintenance budget for the Black Hawk manufacturing department

Supported to coordinate Engineering activities inside the department

Worked with the planner to prioritize and manage the maintenance backlog for the department

Responsible to create a process control development plan, updating and changing of plan when change occurs within the manufacturing process

How is that Six Sigma and Lean connected:

Six Sigma:

Emphasizes the need to recognize opportunities and eliminate defects as defined by customers Recognizes that variation hinders our ability to reliably deliver high quality services

Requires data driven decisions and incorporates a comprehensive set of quality tools under a powerful framework for effective problem solving

Provides a highly prescriptive cultural infrastructure effective in obtaining sustainable results

Defining the term Lean:

Focuses on maximizing process velocity Provides tools for analyzing process flow and delay times at each activity in a process

Centers on the separation of "value-added" from "non-value-added" work with tools to eliminate the root causes of non-valued activities and their cost

Provides a means for quantifying and eliminating the cost of complexity

The 8 types of waste / non-value added work :

Wasted human talent – Damage to people: Sickness or Injury or unscheduled breaks Defects – Things which are not right from the perspective of a process & needs fixing

Inventory – Parts or Products waiting to be worked

Overproduction – Parts or products too much/too early in line of production

Waiting Time – People waiting for parts or raw materials to arrive in every station

Motion – Unnecessary human movement

Transportation – Moving people & unwanted products or equipments

Processing Waste – Things we have to do that doesn’t add value to the product or service we are supposed to be producing.

DMAIC to Improve Service Processes

No matter how we approach deploying improvement teams in the organization, we will all need to know what is expected of them.

That is where having a standard improvement model such as DMAIC (Define-Measure-Analyze-Improve-Control) is extremely helpful.

DMAIC is a structured, disciplined, rigorous approach to process improvement consisting of the five phases mentioned, where each phase is linked logically to the previous phase as well as to the next phase.

The main focus on this project/Intern which took into consideration the extensive usage of the Lean Six Sigma DMAIC process in a service environment, including both methods and tools that are particularly helpful as well as hints on how to model the people, equipments and customers of every phase.

5S System

Another important tool used in this intern was the 5S system of organization.

The main theme or the motive behind the usage of this 5S tool is that a messy workplace, desk, or manufacturing cell makes it hard to find things, easier to get distracted, and can introduce accidents or mistakes.

The “5S” stands for:

1. Sort – Sort needed and unneeded items2. Set in Order – Arrange things in their proper place

3. Shine – Clean up the workplace

4. Standardize – Standardize the first three S’s

5. Sustain – Make 5S a part of the job (make it ongoing)

From this Internship, I believe that 5S is a must-have tool in every manufacturing/production industry. For any of the tools in the toolkit for becoming lean- a quick changeover, total productive maintenance, and mistake-proofing is the most important or essential factor to be taken into consideration.

5S significantly helps in both the implementation and sustaining of improvements. The Gold Standard for 5S is that anyone should be able to find anything in their own workplace in less than 30 seconds, and anywhere else in the workplace in less than 5 minutes without talking to anyone, opening a book or turning on a computer.

Six Sigma Vs Lean Thinking

Six Sigma is problem-focused tool, with a view that process variation is waste. Lean Thinking, on the other hand, is focused on process flow and views any activity that does not add value as waste.

Six sigma uses statistics to understand variation.

Lean uses visuals: Process Mapping, Flowcharting, and Value stream mapping, to understand the process flow.

Program Six Sigma Lean Thinking

View of Waste Variation is waste Non-value add is waste

Application

1. Define

2. Measure

3. Analyze

4. Improve

5. Control

1. Identify Value

2. Define Value Stream

3. Determine Flow

4. Define Pull

5. Improve Process

Tools Math-Statistics Visualization

Focus Problem focused Process flow focused

The above table gives us a comparison between Six Sigma and Lean Thinking with certain standards of comparison like View of waste, Applications, necessary tools to operate and the prime focus involved in each category.

Subjects useful for this Intern:

I felt that the extensive usage of certain subjects which benefitted me during the internship were:

Advanced Engineering Statistics

Production and Inventory Control

Metrics and Measurement systems

Logistics Distribution/Transportation systems design

Facilities Planning

Advanced Automation and Manufacturing systems

Simulation and Optimization

I take this opportunity to thank Dr.John Priest and Dr.Sheik Imrhan for the guidance and evaluation of my Intern with Stanley works by encouraging me at every possible step with their academic and professional expertise. The importance of this internship gave me an insight for the latest technologies involved in big companies in meeting their immediate competitors to survive the current market.

I specially thank Dr. Boardman, for her excellence in teaching and bringing practical examples to the class and her approach to the problem solving techniques which helped me and benefitted me on a great deal.

I also thank Mr.Paul Gerbi who guided me and helped me in understanding and learn various industrial expertises involved in a shop floor for efficient and profitable management of a maintenance operations. He also taught me how to handle different people from laborers to higher officials. Through him I learnt a great deal of people management skills. I can now rate my people skills (excellent) which is one of the most important skills for an efficient maintenance operations from this internship’s perspective.

References:

www.Stanleyworks.com

Lean Hand book for Industrial Engineers- University of Michigan Ann Arbor

http://www.strategosinc.com/lean_benefits_1.htm

http://ezinearticles.com/?The-Advantages-of-Lean-Manufacturing&id=784987