Standardization fixture and Scrap reduction on forging ... · Standardization fixture and Scrap...
Transcript of Standardization fixture and Scrap reduction on forging ... · Standardization fixture and Scrap...
© 2013 Eaton. All Rights Reserved.
Standardization fixture and Scrap reduction on forging press 24
VG EMEA
Bosconero Plant
January 16,17,18,19 2017
2 © 2013 Eaton. All Rights Reserved.
RIE Team
Stefania Giacometti
Opex Snr Analyst
Nauman Ali
Quality Engineer
Giovanni Basso
Preparation area
supervisor
Cristian Volta
Operator
Team
Ditta Marchiò
External Supplier
Paolo Ambrosino
Shift spv
Giuseppe Cimino
Quality Mgr
Daniel Kavanagh
CI EMEA Mgr
Marco Di Tria
Operator
Max Defilippi
Shift spv
Antonio Antonucci
Operator
Adriano Carpino
Operator
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Area Profile Sheet Area Profile
Rapid Improvement Event Area Profile Team # :
Event Dates:
RIE Standardization of forging fixture to reduce scrap January 16-17-18-19th Y2017
Preliminary Objectives: Team:(Name & Function)
1) Identify and eliminate safety issues during the event Team Leader Cimino Giuseppe
2) 5S+ Improvement in the identified area Prod Basso Giovanni
3) forgin press 24 quality improvement(slugs handling/slugs segregation,restart production procedure) Qual Ali Nauman
4) improve ergonomy during setup phase CI Giacometti Stefania
5) improve process check Prod Defilippi Maxmiliano
6) revise Standard Document: 5s+ Autonomus Maintenance, Pre-shift startup; STDWork Prod Ambrosino Paolo
8) update the LSW to ensure FLL check the new standards are being Prod operatore
9) Quality process parameter control during forgin CI EMEA kavangh Danial
EHS Mauro Volpe
x x
x
x x
x x x
x
x x
Production Requirements (Takt Time): Linked to what strategic goal and High 5 Metrics?
na CONC , TRCR, OTD, FLEX,
OEE,
Process Information: Current Situation and Problems
1.the forging area need 5s improvement
2.slugs are not well identified on boxes(too hot/toocold/restart part/go after approval
3.machine parameter not always under control4. simplified documentation on work station fi is possible move to electronic form
5.no systemation approach for process check
6.std document need to be review
2016FY FL % scrap
% scrap c/o forging 0,43%
TOOLS USED TO ACHIEVE AND SUSTAIN OBJECTIVES-ELSS/CIF
VSM
5S+
STANDARD WORK
TPM
Manning Strategy
Daily Accountability
Gemba Walk
CI for everyone
LEAN MATERIAL FLOW
6 SIGMA
Process Standardisation
Visual Controls
Process Checks
101204
Scrap pcs
ADKAR
Other(Specify)PROBLEM SOLVING KAIZEN Leader Standard Work
SUR
21 23 24 25 26 27 28 29 STA
JANUARY 1,8% 2,0% 2,2% 0,8% 1,2% 1,4% 1,9% 1,7% 1,5%
FEBRUARY 1,4% 1,9% 1,7% 0,7% 0,8% 0,9% 3,0% 1,8% 1,3%
MARCH 1,6% 2,5% 2,6% 0,6% 0,8% 1,7% 2,5% 2,1% 1,6%
APRIL 2,0% 2,3% 1,8% 1,1% 1,1% 1,3% 1,8% 3,1% 1,7%
MAY 2,3% 1,9% 2,0% 0,9% 1,4% 1,4% 2,3% 2,2% 1,6%
JUNE 1,7% 1,9% 1,4% 1,0% 1,6% 1,3% 2,2% 1,8% 1,6%
JULY 1,5% 1,5% 2,1% 0,7% 1,4% 0,9% 2,0% 1,8% 1,3%
AUGUST 1,7% 1,1% 1,6% 0,8% 1,5% 1,2% 3,0% 2,2% 1,4%
SEPTEMBER 1,1% 1,2% 1,8% 0,8% 1,2% 1,0% 1,2% 2,0% 1,2%
OCTOBER 1,1% 1,4% 2,5% 0,7% 1,2% 0,9% 1,4% 1,5% 1,2%
NOVEMBER 1,5% 1,5% 2,9% 0,7% 1,0% 1,1% 2,4% 1,5% 1,3%
DECEMBER 1,1% 2,1% 2,1% 0,9% 1,2% 1,4% 2,2% 0,0% 1,4%
YTD 1,5% 1,7% 2,0% 0,8% 1,2% 1,2% 2,1% 2,0% 1,4%
SCRAP % ON PIECES
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Daily Progress Target Sheet
Target
Start Target
Identify kaizens (Safety Hazard and others) and remove 0 20
Ergonomy Improvement 0 1
Update 5s+ std 0 1
Autonomus Maintenance improvement 0 1
pre-shift startup improvement 0 1
simplified current documentaion 0 1
reduce scrap on press 24 2% 1,20%
Visual Control 0 1
Process Check Improvement 0 1
LSW creation 0 1
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Before Current Condition
The forging area need 5s improvement
Slugs are not well identified on boxes(too hot/toocold/restart part/go after approval
Simplified documentation on work station fi is possible move to electronic form
No systematic approach for process check
Standard documents need to be review
Current scrap rate 2%
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Team Approach Approach
Day 1
• Safety Red
• Brainstorming to share improvement ideas
• Plan of Attack
Day 2 - 3
• Quality improvement focus day
• Kaizen closure
• CIF tools implementation
Day 4
• Training
• Lesson Learnt
• Follow - Up
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RIE Kaizen Newspaper
Identified 15
Closed 15
Identified 27
Closed 23
SAFETY
Other
KAIZEN
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5S Activities
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Safety and Quality Improvements BEFORE AFTER
• Pressure gauges are without visually indentified
limits
• Graphite containers are not identified acording
to their type, risk of making mistake during filling
• The two grafite continers are positioned very
high from the floor (operator need to load the
cylined making a movement of tak above his
shoulder
• Pressure limits on gauges are more visible
• Graphite containers are indentified for each type,
eliminate the risk of mixing one with other
• The two container have been positioned in a proper
way to improve ergonomic.
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Improvement made
BEFORE AFTER
• Lot of papers work documentation
spread on working table, making
confusion
• Most of paper work is going to be
move on electronic file. Operator
will work directly on PC station.
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Improvement made BEFORE AFTER
• Boxes for hot and cold slugs are not identified
• Hot slug box is not covered and locked
• Possible risk of mixing good slugs with bad
• ISHIKAWA analysis also confirms the under
subject root cause box identification
• Boxes for hot and cold slugs well identified with
red and blue colour
• Hot slug box is covered, locked and equiped
with trolly
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Improvement made
BEFORE AFTER
• At the exist of forging press, forged valves
exist with very high speed while they are
hot (≈ 900 C°)
• Could generating defects on valve profile,
like chipping off the materiale from head
• At the exist of forging press, a
damper has been installed to slow
down the montion of forged valves
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5S+ Improvement made
BEFORE AFTER
• Forging tools are mixed up with other tools
• Risk of mistake during tool change over
• Irregular arrangement of tools and process
documents on desk
• Forging tools are divided by each type
• Process documents are calssified and
arranged
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5S+ Results
BEFORE
AFTER
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5S+ Improvement
BEFORE AFTER
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5S+ Improvement BEFORE
AFTER
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Improvement – New workplace layout
More improved
layout
Reduced the ideal time of
operator
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Waste reduction on Walking
1500 steps / shift
300 steps / shift
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Best Practice Sharing
• The hot slug cut
scraps box have
been replaced with a
more secure and
better ergonomic
container to handling
the scraps
• Advantages:
• Secure mixed
hot/cold slugs
• Better ergonomic as
trolley;
• 5s on shop flooe;
Solution could
be exported to
other forgin
press
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Post Event Target Sheet
Start Target 1st Day 2nd Day 3rd Day 4th Day 5th Day Difference
% Increase /
Decrease
Identify kaizens (Safety Hazard and others) and remove 20 31 5 5 2 NA 4 88%
Ergonomy Improvement 1 1 1 1 0 NA completed 100%
Update 5s+ std 1 0 0 1 0 NA completed 100%
Autonomus Maintenance improvement 1 0 1 0 0 NA completed 100%
pre-shift startup improvement 1 0 1 0 0 NA completed 100%
simplified current documentaion 1 1 1 0 0 NA on-going 50%
reduce scrap on press 24 2% 1,20% NA NA NA NA NA on-going on-going
Visual Control 1 2 1 1 0 NA completed 100%
Process Check Improvement 1 0 1 0 0 NA completed 100%
LSW creation 1 0 0 0 1 NA completed 100%
Remarks: 1. move from paper sheets to electronics file with IT support
2.
3.
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Learning and Sustaining
CIF Tools to sustain:
5S+, Autonomous Maintenance and Pre Shift Start Up standard improvement
Visual Control
Process Check (calendar already in place in the finishing lines) and 5S+ Audit
already in place
Standard Work and LSW updated
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Improvement Plans / Next Steps
1. This solution will be tested during one
month production before possible
extension to other forging pressess
2. Layout review evaluation/optimization
of all remaining forgin press in
preparation area.
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Reflection on RIE Process
Job well done
1. External suppliers cooperation
2. Team Engagement
3. Activities scheduled
4. Active operators partecipation
through shifts
Needs improvement
1. All works properly as planned
What has been
learned
1. «Key people» involved are
essentila to achive the results
Obstacles
• Work on production runninng shift
Suggestion for next RIE
1. Continue to involve operator
using suggetion board
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Summary
Tools Used
VSM
5S+ X
Standard Work X
TPM X
SUR
Problem Solving Kaizen x
Lean Material Flow x
6 Sigma
Process Standardisation X
Visual Controls X
Process Checks X
Leader Standard Work X
Manning Strategy
Daily Accountability
Gemba Walk x
CI for everyone X
ADKAR
Other(Specify)
COST $ SAVINGS $
5000,00
Project Summary
Summary of Results:
•Improved standards for 5S+, Autonomous
Maintenance and Safety Checks
•Quality opportunities for improvement
•Ergonomic improvement found and implemented
•Improved 5S+ for Forging press area 24
1.000,00
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