Tim Conrad, Gates Corporation - Speaker at the marcus evans Manufacturing COO Summit held in Las Vegas, NV, April 16-17, 2012, delivered his presentation entitled Using Lean Tools to Transform Our Business Processes

1. Gates Corporation
Process Improvement Using Lean Tools

2. Gates Powering Progress!

3. Traditional Thinking
• Focus on
machines
hi
• Define Value Add
• Standard Work
• Work Balance
Work Balance

4. Machine Utilization
Urethane Belting
• Target is 85%
1,200
(secs)
PNP Study Cell 6
11/11/10
Target Balance (secs)
YAMAZUMI SUMMARY 510
Utilization
Utili ti Y
CURRENT STATE
Totals
(Seconds)
89 8% Pick and move tool
Takt Time (secs)
600
VA
1,000
• Actual 25.3%
NV 89 8% Pick and move tool NV
NV 89 8% Pick and move finished slab NV
WNC 11 1% Pick and Move Demold WNC
WC 42 4% Crane Wait WC
• Gap = 59.7% 0
0
800
0
0
0
Takt Tim e
600 600
WC 405 38% Wait Choice WC
WNC 197 18% Wait no Choice (Operator) WNC
Target
Balance 510
LD 14 1% Wait (Breakdow n) LD
WN 139 13% Movement w ithout Parts WN
0
400 8 Stop
0
7 LD
0
6 WNC
0
5 WC
0
4 WN
Stop 0 0% Stop Stop 200
3 NV
1076 Total Scan Time At A Glance
14.4 Total Linedown & Breaks VA / WK NV 2 WK
1062 < Linedown & Breaks 89 178
853 < Linedown, Breaks & Wait No Choice Waste NC Waste C 1 VA
670 139
80.38% Position Efficiency Takt Time
25.17% Utilization of Efficiency 600
Target
27 1.53 Total Scans Per Hour 0 1 2
Balance
510
Copyright 2008 Gates Corporation - Rev. 5

5. Machine Utilization
• Why is the PNP not meeting its target? Cause & Effect Stratification Chart
Wait for mold # Molds in Cell Trial to see after Auto
(4) molds run Run mode of PNP
VMM Run-In slow
Operator Utilization: 8 hr Crane home position
Man observation was 85% / Slab drop-off slow
Cord cycle slow Jacket Applicator cycle time
Process System downtime 49 sec/slab to drop & home from top Use schedule to set
reliability
sequence &
Slab pick cycle slow 56% of time: No
priorities?----Est 6%
Moves by PNP
Semi-Auto Mode (All gain
Machine Crane Utilization 25% moves req Op Input)
(8hrs observation)
18% of time: Op
not available to Set Run Mode from
Centering/Homing
initiate PNP Semi Auto to Full
part of Crane moves Slow
moves Auto: Est. 18% Gain
Cord bins too far
from point of use (4 slabs)
Scrap data from
No visual Kan Ban on Mold Marks
Crane delay on
tape for mandrels
YTD, 12 pcs/shift moves
Materials
Pad degradation & swelling scrapped, (0.25 slabs)-----
through life due to wear & Knit tube prep batched
cause defects & demold (Not one-piece flow)
Teflon tubes for knurled pads Pack method contains
wrinkled from supplier extra non-value-added Method changed & operators
handling of belts following: Documentation needs
f ll i D t ti d
Methods to be updated with more detail
Jacket labeling batched
(Not one-piece flow)

6. New Paradigm
• How can we correlate machine productivity
and operator productivity?
d t d ti it ? Plant Name
Position Position Position Position Position Position Position Position Position Position Position Position
Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Efficiency Avg Effici.
52.0% 86.1% 57.3% 98.0% 95.9% 74.0% 97.8% 85.9% 91.2% 64.0% 80.2%
Utilization Utilization Utilization Utilization Utilization Utilization Utilization Utilization Utilization Utilization Utilization Utilization Avg Utiliz.
45.6%
45 6% 66.4%
66 4% 52.6%
52 6% 89.1%
89 1% 83.1%
83 1% 66.3%
66 3% 86.2%
86 2% 77.1%
77 1% 81.1%
81 1% 54.6%
54 6% 70.2%
70 2%
Scan Time
(min)
497.6
Scan Time
(min)
529.4
Scan Time
(min)
501.4
Scan Time
(min)
553.3
Scan Time
(min)
521.8
Scan Time
(min)
540.7
Scan Time
(min)
547.6
Scan Time
(min)
520.3
Scan Time
(min)
518.1
Scan Time
(min)
31309.4
Scan Time
(min)
#VALUE!
Scan Time
(min)
#VALUE!
Lines/Hour
(min)
#VALUE!
Average
Total # of
Operators 70%
10
Operator
Utilization
Utili ti
100%
80%
60%
Build &
40%
Cure only
43%
43%
20%
Operator
Utilization
0%
4508 Cure Cutter BuilderGrind Pack Bank 1 (15 -18) Bank 2 (19-22)
Grind Pack 4501 Builder 4501 Grind/Pack Cut 4501 Cure 4501 Profiler 4501 Shaper 11 12 Average

7. What does this tell us?
• We need to balance
operator utilization Operator “Wait” Observations
t tili ti Operator Wait Observations
with machine Cord Lay
No Mandrels To build
utilization
tili ti No Specs
No Slabs to cut/incorrect
• Studying operator No Stock
utilization will help us Nothing to Do
Mechanical Downtime
see opportunities to Equipment Availability
improve machine No Slabs to grind
Waiting on Mold Handler
utilization Evaluating Quality

8. Results
Optimize
crane
Change
g Add movements
Scheduling cooling
Rules capacity