OUR TOUR OF DJO GLOBAL

SURGICAL MANUFACTURER

This is one of the first things we encountered upon entering DJO’s manufacturing area. It is their scrap table, A.K.A “The Table Of Shame”.Sara Laubach, their plant manager informed us that a team meets there each morning to discuss the root cause of the scrap. At least one memberof manufacturing, one member of engineering, & one member of qualityare present for this meeting.

This is a picture of the machine shop. This is a star turning machine.Just like the one we have on our shop floor. The area is clean and uncluttered. The work for this machine is loaded onto the rack to theright of this machine. If you look behind the spray bottle you will noticea work instruction attached to the machine.

Here is a picture of one of the many mezzanines they had at DJO Global. Lenny and Joe liked this idea. They felt it was a good wayto add storage space to a one story building. In the back ground youwill see the janitorial room. It was super organized and super clean.

This is a picture of one of the many optical comparators we sawat DJO Global. I counted at least four of them on the shop floor.Joe mentioned that having one of these at M2 Global would help us with checking our parts. Especially first article inspections.

Here is a picture of some of the metrics in front of the Q.C. area.They are as follows; PO Lots Received, PO Lots Completed, POLots In QC, PO Parts Completed, & Parts Per Hour. Also if you’ll notice the Q.C. targets/ Vision form in the bottom right corner.Each department had one of these posted .

This is a picture of a Geometric Dimensioning & Tolerance chart.I thought posting one of these in our shop would be a good idea.Lockheed Martin uses a lot of these symbols on their prints and not everyone knows or remembers what they mean. Something likethis Probably doesn’t cost any more than $20.

Here’s another picture of the machine shop.

This is a picture of a material rack at DJO Global. From what I understood this is the way they store their round stock for their lathes. They run a min/max system. Once one of these bins getsdown to a predetermined quantity, materials personnel reorder.

Here is a picture of DJOs tool pre-setter. I took a picture of this because I liked the way they had it set up. I liked the wooden work bench they had it sitting on, I liked the tool box they had under it,and I liked the flat screen they had connected to it.

This is a tool vending machine from J&L industrial supply.DJO had this located next to their tool crib. Vendors such as J&L will place one of these in our shop at no cost as long we meet their annual purchasing requirements.

More pictures of the machine shop.

Mori Seki Mill. Front view of Mori Seki.

More pictures of the machine shop. Each machine has a materials rack next to it and most had one of these mobile ultrasonic carts.

Machine Shop At DJO.

Leblond Horizontal Mill. Walter polishing machine

Walter polishing machine. As a machinist I was very interested in this machine. You should have seen the way it moved and the finished product was amazing.

Polishing/ Grinding Machine.This is the way they hold the knee joint implant.

Inner workings of the Walter polishing machine.

Here are a couple of pictures of the mobile ultrasonic cleaners they had out at DJO Global. We all really loved these and have high hopes of one day installing them in our shop.

These ultrasonic cleaners feature an all stainless steel construction and have the ultrasonic component and heater built in.

Ultrasonic cleaning cart. Front view.

Here is an overview of the machine shop. Towards the front (where you see the vises), is the red tag area. In the middle is the machineshop, where you see several CNCs and sandblasters . In thebackground you see another mezzanine, used for a storeroom.

This is a Kitamura horizontal mill. This work station was very clean and very lean. Only the bare essentials are left out. You can see the Workload rack, a tool box with work surface on top, and also a qualityalert statement for the part they are running on this machine.

These are some of the metrics they had posted out on the shopFloor. Some of the ones that really stood out to me were non-conforming materials received, nonconforming materials from in house W.O.s, and sales or $ shipped vs. site payroll.

Here are some more of the operations metrics they had posted.Very plain and very visible in the shop floor for everyone to see.Employees and visitors alike. Scrap rates, lead times, and WIP turns.