Packaging Specialties of Georgia Mistake Proofing Submission A3 used by the Kaizen Team Issue: Hoses being cut to wrong size When cut too long, the hose will crease. Ultimately causing a cracking and leaking. Examples below are based on one occurrence Old way. Old hoses were laid flat and used a guide for length of new hose Rarely did we get the correct size- Just over 50% more cost (labor & material) Cracked hoses caused hours of extra cleaning that can be eliminated Ties up Man Hours on one task for too long No Visual Markings on Machine for what the length should be High risk of getting cut with box knife Kaizen Team Came Up With A Better Way! Old vs.. The New- Simple Jig was made to ensure correct size every time ($30 to make). Correct size ensures no creases and/or cracks which means no spills and no costly downtime. This simple improvement will reduce change time by 25% Giving back $ in supply/labor cost every 1500 hours. THANK YOU!