Atlanta Beverage Folding Carton Facility

CI 1100 5s Fall 2013

Initial Conditions

Disorganized and cluttered workspace.

Unnecessary movement of aniloxes.

Lack of anilox cleaning and standardization;

resulting in product defects.

Excessive storage space and inventory of unused

plate sleeves.

Excessive motion necessary to move equipment

press-side.

Team Members

Frank Humphries Line Lead Georgia Stephens Pre make ready specialist

Rodney Lomax Shift Lead Quinton Jones Pre make ready specialist

Michael March Operator Johnnie Robinson Operator

Shawn Gregory

Co-op student engineer

Improvement Opportunities Identified by Team

Tasks were divded into four

disciplines: general, anilox, mandrel, and

plates.

Each discipline had a procession of

events based on priority and prerequisit

actions.

Much of the work focused on

improving the transportation and maintenance

of aniloxes and sleeves.

It was proposed to rearrange large

capitol items in order to increase workplace

flow.

Work on project when not making the

line ready or firefighting down time.

Accomplishments

Sorted, Set, Shined, and standardized mobile Doctor

Blade, Deck Rebuild, and everyday tool carts.

Standardized PM tool box, mounted on castors for

press side use.

Created Anicam station and SOP on anicam.

Standardized anilox tracking document and forecaster.

Trained operators on anicam data documentation.

Mobile plate sleeve carts

Cleaned press side table and created die and delivery

tool area

Results

Potential is in place for paperboard waste

reduction via cleaner aniloxes once washer is moved

in January. Also, excessive anilox transportation

will be cut.

Mobilizing carts and tools have played a role

in decreasing average operational downtime and

make ready times.

All aniloxes are inventoried by serial

number, original BCM and LPI, and will be updated with a current BCM count.

Future Actions

Begin to phase out old and damaged mandrels, plate

sleeves, and aniloxes.

After washer is installed, have washer modified to

hold aniloxes with caps, and paint caps according to

BCM.

Remove old racks.

Have anilox racks cut so they become mobile.

Work excessively with new plate mounter so removal

of old mounter is expedited.

Build or purchase press side container for cook kit.

Anilox Pores

Figures 1 & 2: Spaghetti diagrams show the reduction of transportation waste associated with adding and removing aniloxes from the press. Batch removal and instillation are now

possible due to the condensed anilox maintenance station and modified transportation rack.

Figures 3 & 4: Cart used to change doctor blades is now standardized with a prescribed list of tools and parts.

Figures 5 & 6: Tool box used for non-PM downtime was cleaned and removed of excess clutter. Box was placed on castors to reduce excess transportation and facilitate quicker

repairs.

Figures 7 & 8: Table top for data recording and tooling was cleaned and standardized.