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Material Handling Kaizen Report OutFinished Assembly Tugger Delivery
Utica
June 27, 2008
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Finished Goods and Purchased Part Delivery Tugger System
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Team
Doug Tegtmeier, Andy Scott (Team Leader), Lori Kinzer, Dwight Reynolds, Rob FowlerDoug Tegtmeier, Andy Scott (Team Leader), Lori Kinzer, Dwight Reynolds, Rob Fowler
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Charter
Business Case:
TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $.82 The purpose of the event is to establish a Work Standard using a Tugger system to pick up and deliver needed materials to the Assembly cells and pick up and deliver Finished Assemblies to the shipping dock. Currently, There is a one forklift driver dedicated to picking up finished assemblies and taking them to the dock. The Tugger will now pickup and deliver finished assemblies on his regular route.
Business Case:
TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $.82 The purpose of the event is to establish a Work Standard using a Tugger system to pick up and deliver needed materials to the Assembly cells and pick up and deliver Finished Assemblies to the shipping dock. Currently, There is a one forklift driver dedicated to picking up finished assemblies and taking them to the dock. The Tugger will now pickup and deliver finished assemblies on his regular route.
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Charter
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Work Standard Elements
Work Elements
0.6 Seconds Each step the tugger operator takes (2.5 feet per step)
3.66 Feet per Seconds Tugger Travel Time estimated 2.5 miles per hour
3.9 Seconds Get on tugger
3.9 Seconds Get off tugger
7 Seconds per container Deliver container/ Pick up empty
37 Seconds Unhook empty/ Unhook empty from empty/ move empty to staging area/ re-hook other empty
17 Seconds Walk from stop/ to FG cart/ move FG cart to end of train and hook to train
28.1 Seconds Tugger remove (1) skid from stack and place on empty cart
22.3 Seconds Shipping unload time per (1) full cart
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Standard Work Calculation
PART#STANDARD
PACKPIECES PER
UNIT Daily UsageDaily Total
Usage# of containers
per day# of containers
per hour
# of containers per hour * 7 secs
per container (pickup/delivery)
GA-1054 50 1 72 72 1.4 0.2 1.4
SC-2951 100 2 72 144 1.4 0.2 1.4
SC-989 100 2 72 144 1.4 0.2 1.4
SC-641 200 2 72 144 0.7 0.1 0.7
SC-2944 100 2 72 144 1.4 0.2 1.4
SC-456 1000 5 72 360 0.4 0.0 0.3
MI-3054 200 3 72 216 1.1 0.1 1.0
93.1+7.8+54 sec.Total=154.9 sec. (93.1sec. delivery and pick up of empty
bins + 7.8 sec. to get on and get off tugger + walk time around cell)Total=154.9 sec. (93.1sec. delivery and pick up of empty bins + 7.8 sec. to get on and get off tugger + walk time around cell)
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Time Study
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Number of Skids per Hour/Route.
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1 Hour Coupled Route Parameters
Minimum Requirements for a
one hour route frequency
Time Study #1 Time Study #2 Time Study #3 Time Study #4
Time Study #5 4 Finished
Assembly carts
Max load time
33% of total time
20 min. (0.33 x 60 min.)
7 min. 55 sec. 6 min. 40 sec.
11 min. 26 sec.
13 min. 26 sec. 25 min.
Max travel time
33% of non load time
13 min. 12 sec. (.33 x 40 min.)
*If load time were less than 33% (20
min.), maxim
um travel time could
be greater
.3 min. 40
sec. 3 min. 40 sec. 3 min. 40 sec. 3 min. 40 sec. 4 min. 40 sec.
Total Stop Time 27 min.
11 min. 10 sec.
13 min. 52 min. 9 min. 6 sec. 7 min. 15 sec. 21 min. 48 sec.
Total Time 60 min.
22 min. 45 sec.
24 min. 12 sec. 24 min. 4 sec.
24 min. 21 sec.
51 min. 28 sec.*
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Kaizen Title
Operator No. Problem Measures Taken Results
Remarks
Name
Kaizen Sheet
1.1. Forklift were being used to move final
assemblies to shipping
Forklift were being used to move final
assemblies to shipping
Tugger will now take final assemblies to
shipping dock.
Tugger will now take final assemblies to
shipping dock.
Reduction in forklift waste
Reduction in forklift waste
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Kaizen Title
Before Kaizen After Kaizen
Operator No. Problem Measures Taken Results
Remarks
Name
Kaizen Sheet
2.2.No Signs for
assembly cellsNo Signs for
assembly cellsAdded signs above each assembly lineAdded signs above each assembly line
Better visual controlsBetter visual controls
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Kaizen Title
Before Kaizen After Kaizen
Operator No. Problem Measures Taken Results
Remarks
Name
Kaizen Sheet
3.3.Hard to get
leads in fixed tubes
Hard to get leads in
fixed tubes
Unscrewed lead tubesUnscrewed lead tubes
Each part has two tubes and
tugger and take one to fill
Each part has two tubes and
tugger and take one to fill
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Kaizen Title
Before Kaizen After Kaizen
Operator No. Problem Measures Taken Results
Remarks
Name
Kaizen Sheet
4.4.
Skid stacks were stacked too high for tugger to
reach
Skid stacks were stacked too high for tugger to
reach
Lowered signsLowered signs Controls stack hieghtControls stack hieght
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Kaizen Title
Before Kaizen After Kaizen
Operator No. Problem Measures Taken Results
Remarks
Name
Kaizen Sheet
5.5.Used forklifts, walk behind
forklifts to move final assemblies (Safety
issues, inefficient material movement methods).
Used forklifts, walk behind forklifts to move final assemblies (Safety
issues, inefficient material movement methods).
Started using a tugger vehicle to supply
assembly with parts and take final
assemblies to shipping dock
Started using a tugger vehicle to supply
assembly with parts and take final
assemblies to shipping dock
Optimal material delivery method.Optimal material delivery method.
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Improved Delivery Route
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Report Card/Newspaper
Paint lines on floor for cart staging Label carts when arrive with cell indicator and
skid part numbers Job responsibility list
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Report Card/Newspaper
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Questions?