Example 4

PDCA
Team Name:
H-F - Okuma Cell
Topic: Rapid Availability - Cycle Time Reduction
1. PROBLEM STATEMENT:
In April 2014, it was noted that the cycle time for stainless and monel closed cages was 38 minutes and 24
seconds. Our target cycle time, based on customer pace of sales, is 25 minutes or less.
Team Members: Mat Lowe, Eduardo Lozano, John Stukanov, Steve Pittman, Derrick Hey, and Neil Thomas
4. ROOT CAUSES:
Feed & Speed
Programming
5. SELECTED COUNTERMEASURES
Cycle time issue exposed due to recent demand increases and process improvements. Old method was
produced with 5 different machines, and hundreds of parts in WIP. New method was able to perform all 5
functions on 1 machine.
HSS vs. Carbide
(Sandvik Jig mill)
3
GOAL STATEMENT:
By June 27, 2014, cycle time for stainless and monel closed cages
will be ≤ 25 minutes.
HSS vs. Carbide
(Wolfe Jig mill)
2. CAUSE-EFFECT ANALYSIS
Start:
Target:
Finish
Collect tool/insert vendor speeds & feeds
Derrick, Steve
4/7/14
4/7/15
4/7/15
Verify & make adjustments to programs
John, Mat, Neil
4/8/14
4/8/15
4/8/15
Mat, Neil, Eddie
4/10/14
4/11/14
4/11/14
Derrick, John
4/14/14
4/15/14
4/15/14
Contact Sandvik for application review / tool availability
Derrick, Steve
4/16/14
4/21/14
4/21/14
Order tooling for testing
Steve , Derrick
4/21/14
5/14/14
5/21/14
Test new carbide jig mill
John, Mat, Eddie
5/21/14
5/23/14
5/23/14
Modify design & test again
Derrick, Steve, John
5/26/14
6/15/14
NA
Determine application of tech from Wolfe Racecraft
Neil, Derrick
6/2/14
6/4/14
6/4/14
Test new jig mill from Wolfe
Mat, John, Derrick
6/9/14
6/16/14
6/12/14
Verify results & test other size jig mills (6)
John, Derrick, Eddie
6/16/14
6/20/14
6/20/14
Develop std speed/feed settings for each size jig mill
John, Steve, Mat
6/16/14
6/20/14
6/20/14
Develop min/max levels for each size with DXP
Neil, Derrick
6/18/14
6/20/14
6/20/14
Place order through DXP (tool, insert, screws)
Derrick
6/20/14
6/20/14
6/20/14
Change all programs to use new jig mill
John, Steve
6/16/14
as needed
NA
Train operators on new tool & insert replacement
Mat, Eddie, Neil
6/18/14
6/25/14
6/24/14
Tool Performance & Tool Breakdown & Analysis
Function - Jig Mill
Verify & make adjustments to jig mill in program
UNDERSTAND THE CIRCUMSTANCES:
Affected cage diameter: 2.28 - 3.25" - about 40% of all closed cages.
Who:
Start Date: April 4, 2014
6. RESULTS:
By switching to the Wolfe Jig mills, we are seeing an annual savings of over $129,000 3. DATA COLLECTION (HYPOTHESES TESTING)
By adjusting our tool/insert speeds and feeds to tool vendor recommendations, we will see a reduced
overall cycle time.
7. SUSTAIN:
We predict that by modifying the speed, feed, and tool path (material removal method), of our slowest
tool, we will see a reduced overall cycle time.
●Determined min/max levels and setup through our third-party
●Ordered jig mill in all sizes (within dept.)
inventory management service (DXP).
●Converted all programs to new jig mill specifications.
133L1 Cage ●Modified all setup sheets to reflect new jig mill .
●Trained all employees on new jig mill, including replacing inserts, etc.
Jig Mill Tool We predict that by converting the jig mill tool to a carbide style, we will be able run our tool more
efficiently, seeing an overall reduction in cycle time.
8. RECOGNIZE / SHARE ACHIEVEMENT:
Our improvement was able to be shared across other departments throughout our
facility, all which yielded similar results. We were also recognized in our monthly
company Continuous Improvement meeting and received our prestigious Kaizen
Orange award. This improvement was a catalyst for our company, in regards to the
conversion of HSS to carbide tooling.