TPI Kaizen Event

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Brandon Garrett

Reflector Value Stream Dent Defect Reduction/Elimination Kaizen Event

Empresariales Tecnología

Reflector Loop Dent Quality Focus Kaizen Event November 9th, 2007

Angela Burge, Ryan Walters, Missy White, Larry Meadows, Brandon Garrett, Eric Simmons, Chuck Morgan

Business Case /Strategic Alignment Target/Goal Deliverables Opportunity Scope Team In 11/5/07 Kickoff/training/review data and Process 11/7/07 Root Cause and Brainstorm Solution 11/6/07 Root Cause In FY07 the Indiana Production Facility scrapped appox $882K to the Reflector Value Stream. $128K of the total scrap was due to dents. This negatively impacts delivery to the customer affecting the Gotham KPI target compliance. Out ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Larry Meadows (Process Owner – Team Lead)) Brandon Garrett (Quality) Missy White (Anodizing) Chuck Morgan (Process Owner) Eric Simmons (Set Up) Ryan Walters (Set Up) Angie Burge (Cell Owner) Jeff Rizer Root Cause Analysis 11/7/07 Brainstorm and Validate Solution Report Out 11///07 Timeline KPI – Target Compliance BTO/AIP/KPI IPF 11/5/07 – 11/9/07 Process Owner Associated VSM Cost Center Tool/Method ABS Contact Location Dates Patrick Curtin Gotham 0464

Dent Defect Classification ,[object Object],[object Object],[object Object],[object Object]

Dent Data Collected ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Kaizen Title Kaizen Sheet Reflectors being dented during punch press operation Re-visited Standard Work and translated to all cells. Trained all operators. Reflector Loop Dent Kaizen Standard Work not visible in all cells. Operators trained. ,[object Object],[object Object],[object Object],[object Object],[object Object],Before Kaizen After Kaizen Operator No. Problem Measures Taken Results Remarks Name

Kaizen Title Kaizen Sheet Reflector Loop Dent Kaizen No 5S or Standard Work for Buffing Fixtures causing dents Posted Quality Alert in all cells, trained all operators, adding quality alert to S.W. process. Audit-able dent prevention method. No documentation available. Before Kaizen After Kaizen Operator No. Problem Measures Taken Results Remarks Name

Kaizen Title Kaizen Sheet Reflector Loop Dent Kaizen Widespread improper application of 501 Bent/Dented scrap code. Trained all Reflector Loop personnel on importance of accurate scrap reporting. Reduction of non applicable scrap codes available to operator(s). Before Kaizen After Kaizen Operator No. Problem Measures Taken Results Remarks Name

Creating a New Process ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Creating a New Process ,[object Object],[object Object]

Training ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Parking Lot ,[object Object],[object Object],[object Object],[object Object],[object Object]

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TPI Kaizen Event

1. Reflector Loop Dent Quality Focus Kaizen Event November 9th, 2007

2. Angela Burge, Ryan Walters, Missy White, Larry Meadows, Brandon Garrett, Eric Simmons, Chuck Morgan

7. Kaizen Title Kaizen Sheet Reflector Loop Dent Kaizen No 5S or Standard Work for Buffing Fixtures causing dents Posted Quality Alert in all cells, trained all operators, adding quality alert to S.W. process. Audit-able dent prevention method. No documentation available. Before Kaizen After Kaizen Operator No. Problem Measures Taken Results Remarks Name

8. Kaizen Title Kaizen Sheet Reflector Loop Dent Kaizen Widespread improper application of 501 Bent/Dented scrap code. Trained all Reflector Loop personnel on importance of accurate scrap reporting. Reduction of non applicable scrap codes available to operator(s). Before Kaizen After Kaizen Operator No. Problem Measures Taken Results Remarks Name

10.

11. The New Process

12.

13. Report Card

14.

15. Q & A

Notas del editor

平準化はグローバルプロダクションシステム（ GPS) の礎を築くものです。これが基礎となりジャスト・イン・タイムと自働化の 2 本柱を支えています。現場改善と生産準備を実施していくつもの改善を達成したとします。さらに顧客により早く対応出来るようになりました。しかし、顧客から受ける多くの注文は現在でも変化に富み、注文通り、時間通りに物が造れていません。この変化に富んだ注文サイクルは、顧客が望む日程で我々が製品を配達できていないという不信感からきていたことをつきとめました。この信頼の欠如が、一括注文システムや早期注文につながっているのです。この状況を変えるために、顧客との信頼関係を築く必要があります。平準化は簡単には実施できません。しかしながら本質は、やるか、やらないかです。よって挑戦することをためらう必要はありません。平準化無くしては、我々が実行してきた多くの改善が最大の効力を発揮させることが出来ないのです。株式会社　新技術研究所
平準化はグローバルプロダクションシステム（ GPS) の礎を築くものです。これが基礎となりジャスト・イン・タイムと自働化の 2 本柱を支えています。現場改善と生産準備を実施していくつもの改善を達成したとします。さらに顧客により早く対応出来るようになりました。しかし、顧客から受ける多くの注文は現在でも変化に富み、注文通り、時間通りに物が造れていません。この変化に富んだ注文サイクルは、顧客が望む日程で我々が製品を配達できていないという不信感からきていたことをつきとめました。この信頼の欠如が、一括注文システムや早期注文につながっているのです。この状況を変えるために、顧客との信頼関係を築く必要があります。平準化は簡単には実施できません。しかしながら本質は、やるか、やらないかです。よって挑戦することをためらう必要はありません。平準化無くしては、我々が実行してきた多くの改善が最大の効力を発揮させることが出来ないのです。株式会社　新技術研究所
平準化はグローバルプロダクションシステム（ GPS) の礎を築くものです。これが基礎となりジャスト・イン・タイムと自働化の 2 本柱を支えています。現場改善と生産準備を実施していくつもの改善を達成したとします。さらに顧客により早く対応出来るようになりました。しかし、顧客から受ける多くの注文は現在でも変化に富み、注文通り、時間通りに物が造れていません。この変化に富んだ注文サイクルは、顧客が望む日程で我々が製品を配達できていないという不信感からきていたことをつきとめました。この信頼の欠如が、一括注文システムや早期注文につながっているのです。この状況を変えるために、顧客との信頼関係を築く必要があります。平準化は簡単には実施できません。しかしながら本質は、やるか、やらないかです。よって挑戦することをためらう必要はありません。平準化無くしては、我々が実行してきた多くの改善が最大の効力を発揮させることが出来ないのです。株式会社　新技術研究所

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