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Pallet Car Change-Out ImprovementKaizen
(Kaizen- to tear apart and make better)
www.magnetation.com
February 20, 2015
The TEAM
Evan Mills
Lisette Johns
Mark Kelley
Wolf Solomon
Brian Grimes
Project Targets: 30 days and 6 Months1. Current State “Do It Now’s”2. Future State Ideal, “As Should Be”
• Eliminate all Safety Hazards- 100% – As measured by count of hazards: pinch points,
etc. • Eliminate all unnecessary Wasted time by
100% (short cuts are NOT an option)– As measured by seconds, from grate stop to grate
start.
Training!
The Team Takes Care of the Team
• Mark and his sweetheart candy– Love, Evan and Lisette!
• We couldn’t pull people off of the 5S activity!• Challenged each other, especially during
problem solving brainstorming time. • Team Tackled the Coffee Maker!
Workplace Organization Improvements, 5sWolf
Before and After
Before and After
Before and After
Before and After
Before and After
Safety ImprovementsLisette
• Original Count of Concerns:36• Current Count of Concerns based on
STANDARD WORK (do not vary from standard work!): 20
• 44% reduction in risks
Standard Work InstructionsMark
Brian- tell us how it’s supposed to be!Future Designs
What’s the ROI to pay for all this? Where’s the House $ come from?
Evan
Move this Metric!
5 min avg to 4 min avg• Standard Work
– Data tells us 4 minute C/O has been done recently. So it exists, it can be.
– However our AVG time is 4.92 minutes.
– Our RANGE is 4:00 – 7:15 minutes.
– Why? Variation between how each one is done is the biggest reason.
4 min avg to 3 min avg• The rest of the inefficiency
as defined by our sub process stop-watch– Engineering/ physical changes
Value Add vs Non-Value Add
30 Days or Less Master List
• Easel paper hanging up
6 month Master List
• Hands off• 3 minutes
# Xs Description Parking Lot Validation Strategy Vital Validation Results & Comments
Brief description of the potential Design Y/N
How will we validate? Tools used?
Hypothesis Test, Pilot Simulation etc. Y/N
Validation conclusions; p-values; comments
Design 1 Install grating at c/o N Pilot Y
Design 2
Lengthen distance crane can travel closer to furnace N
Simulation- crane speed vs chain speed over same distance N
Design 3
Design 4
Design 5
Design 6
Potential Design Validation Strategy Summary Sheet
Project Y Engineer Out Waste and Safety Hazards
If necessary use multiple pages.
Controls
• 30 Day Follow Up• Owners• Tracking• Visual Management
How Did We Do?
• Good? Real good?!? – “As Measured By”
• 44% reduction in safety risks• $506,941.20 year gained in Furnace Uptime
(raw)• $477,741.20 year after Depreciation, gas…– This is *one year* folks. What is 5? 10?...– Sources: Pi, Videos, SME’s, Controller, CRO Reports,
Field Trips
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