Island Of Excellence Presentation

Island of ExcellenceIsland of Excellence

Safety Housekeeping Results Oriented

Maintenance Continuous

Improvement Activities

Short Term Results Long Term Results


A Focused Reliable Method to Elevate Machine Condition and Performance to Sustainable World Class Levels

• Break away from the “Status Quo”

• No more of the “Same Old, Same Old”


An improvement process:• Focused events with a dedicated team• Machine condition and performance - achieve significant

results in a short period of time

Phase 1 – Manufacturing Basics• Ensure that machine and processes are safe, clean,

organized, well maintained and capable of achieving world class performance results

– Safety, Housekeeping & Results Oriented Maintenance

Phase 2 – Performance Results• Sweet Spot Analysis / Top Speed – Non Stop• Set Up Reduction• Downtime Reduction• Continuous Improvement


Goals:

• 1st Year - 2009 - Be the best in (Plant Name)– Machine Expectations = 75% or better (see assessment)– Performance = 100% of Process Reliability Standards

• 2nd Year - 2010– Machine Expectations = 100% or better (see assessment)– Performance = World Class

Create Dedicated TeamCreate Dedicated Team

Dedicated team for each machine:• Machine Operators• Machine Maintenance Champion• Machine Supervisor• One Manager – GM, PM, Supt, QM, PRM, SM, CSM, etc.• Facilitator – may be an outside resource• NOTE – All team members should receive Machine

Specific LOTT Training

Prework:• Machine Goals• Machine Performance Charts• Machine Specs• Top Orders

ExpectationsExpectations

Safety Housekeeping Results Oriented Maintenance Continuous Improvement Activities Short Term Results Long Term Results

Team will complete an Island of Excellence Assessment to benchmark current condition and create an Action Item List identifying opportunities to improve machine and processes

SafetySafety

Machine is configured to be as safe as possible• Guards, Curtains, Safety Signage, Organization, etc.

Safety Reliable Methods are a way of life• Standard LOTT Design, Boards & Training Procedures

• JSAs at machine and understood / followed by all

• No duct tape or baling wire on machine– these are a symptom of something that has not been corrected properly

The goal is ZERO incidents• Safety Incidents can cause unnecessary pain and suffering and reduce

machine productivity

• Most Safety Incidents occur in “Upset Conditions”

• The elimination of upset conditions will improve Safety and Productivity

• Safety must never be compromised for productivity

SafetySafety

HousekeepingHousekeeping

A Place For Everything & Everything In Its Place• Machine Area Layout – indicating proper layout and location of

LOTT Board, scrap, waste cans, tools, cutting dies, printing plates, equipment, etc

• All tools readily available with a designated place

The Machine “Sparkles”…• Clean Surfaces• Buff Paint • Proper Lighting• Deep Cleaning

Housekeeping – Machine - ExternalHousekeeping – Machine - External

Before

After

Housekeeping – Machine - InternalHousekeeping – Machine - Internal

Before

After

Housekeeping - OrganizationHousekeeping - Organization

Results Oriented MaintenanceResults Oriented Maintenance

Team approach b/w Maintenance & Operations• Machine Maintenance Champions

Maintain OEM (Original Equipment Manufacturer) Condition• Essential Equipment Care

– Housekeeping, Lubrication, Preventive Maintenance, Calibration

– don’t just repair the problem - determine root cause of failure & eliminate

– PM’s Scheduled & Completed on Time Document all Work with Work Orders Plan & Schedule all Non-Emergency Work Maintenance Planning Meeting Use History to Improve the Quality of PM’s Condition Monitoring

• All machine controls & gauges are clearly and professionally identified The ultimate objective is zero unplanned downtime

Condition MonitoringCondition Monitoring

Condition MonitoringCondition Monitoring

Continuous Improvement ActivitiesContinuous Improvement Activities

Goals• Performance Ratio, Downtime, Speed, Set Up Time, Waste, etc.

Performance Tracking• Charting at Machine• LED’s

Recognition & Accountability Crew Meetings - Action Plans

• Daily Downtime Meetings (if DT over target level)

Machine Calibration & Centerlining Top Speed - Non Stop

Phase One – Manufacturing BasicsPhase One – Manufacturing Basics

Island of Excellence Assessment• Benchmark current condition and performance• Measure Improvement

Action Plan• What needs to be done, by when and by whom• Flipcharts at machine

Crew Meetings• Follow up with Action Plan during regularly

scheduled crew meetings

Phase 2 - Top Speed - Non StopPhase 2 - Top Speed - Non Stop

Agree on Machine Capability• Machine Specs

Sweet Spot Analysis• Identify machine Sweet Spot• Identify Top 10 Orders by quantity & frequency• Choose “Focus Jobs” from Top 10 orders that

fall within the Sweet Spot• Sweet Spot Analysis results should be used by

Sales & Customer Service to better understand whether a job runs with higher or lower productivity and by scheduling to determine which machine is best for each order

Sweet Spot AnalysisSweet Spot Analysis

Width (Machine Direction)

Len

gth

(Cro

ss M

achi

ne D

irec

tion

)

0-15 15-25 25-35 35-45 45-55 55-65 65-75 75-85 95-97 97+

0-10

10-15 10

15-20 3

20-25 2 1 9

25-30 8

30-35 6

35-37 5 4

37-48 7

48+ Out of Machine Capability

Reduced Rate

Sweet Spot – Max Speed


Top Speed Non Stop• Goal is to run top sweet spot orders at top

machine speed with minimum downtime (without affecting safety & quality)

• Effective preparation is key:– Safety, Housekeeping and Preventive Maintenance must

be addressed ahead of time– Orders must be scheduled, cutting dies and printing

dies must be in good condition, and all materials must be ready to go

• Increase speed incrementally to identify issues and eliminate – keep detailed log during process – “Hit the Fast Button”


Top Speed Non Stop

• The exercise should show that significant performance improvement is possible if everything is organized effectively and machine speeds are pushed

• The challenge is to get the processes in place to be able to sustain top speed on an ongoing basis in future

Short Term ResultsShort Term Results

Safe, Clean and Organized Machine & Area

Zero Safety Incidents

100% or greater Machine Performance Ratio• Downtime - less than Process Reliability standard

• Speed - greater than standard

• Set Up Time - less than standard

Long Term ResultsLong Term Results

Single Digit Downtime• Machine & Process Downtime under 5% for Corrugators &

under 10% for Finishing

Average 75% of maximum machine speed

Single minute Set Up Time

Zero No Stock Downtime

Island of Excellence – Top Speed Non StopIsland of Excellence – Top Speed Non Stop

BEFORE


AFTER

The Path To Excellence The Path To Excellence


Machine Performance Ratio

0%

20%

40%

60%

80%

100%

120%

Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec

Before

After!

Your Island of ExcellenceYour Island of Excellence


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• Have A Nice Day

• Questions or Comments?

Contact InformationContact Information

The Box Doctor46 Years Experience - LLCRoger M. Maxson475 Maplebrooke Dr. WestWesterville, Ohio 43082Office/Home 614-899-0473Cell 614-406-6145Fax 614-899-9329E-Mail: [email protected]@[email protected] Site: www.MaxsonContainerConsultants.comSkype # roger.maxson

mailto:[email protected]

http://www.maxsoncontainerconsultants.com/

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Island Of Excellence Presentation