Web 200 ton Warco Setup

Setup reduction 200 Ton Warco
Kaizen Workshop Purpose:
The purpose of this Kaizen Blitz is to improve the ability to respond to
customer’s demand and internal supplies through improved flow of
products, workplace organization and visual management.
Objectives:
1. Reduce changeover time on the 200 Ton WARCO Press by 55%
2. Improve Productivity by 25% with 2 months
3. Improve Workplace Organization and Visual Management
1
Setup reduction 200 Ton Warco
Workshop strategy for success
• Follow a “Proof of concept” approach
• If the concept makes sense, make it work
• Change is Mandatory, not optional
• Everybody needs to have an open mind
• Cost is an excuse, not a reason
• Be part of the solution, not the problem
• Participation & ownership by all team members is critical to sustaining the
changes
2
Setup reduction 200 Ton Warco
Team Picture
3
Setup Definition
Last good part
First good part
The length of time from the last piece
produced to the first good piece produced
4
Training Agenda
Definition of Setup
Setup Reduction Goals
Identifying Setup Problem
Improvement Methodology
Setup Reduction Benefits
Your Improvement Program
5
Setup reduction 200 Ton Warco
Execution:
Plan is for a 4.5 day event with an outside consultant scheduled as follows:
• Day 1
•Present Setup Reduction training
•Document existing setup process
•Separate Internal/External
•Determine Short term/long-term improvements
•Day 2
•Separate Internal/External
•Determine Short term/long-term improvements
•“Try-storming” improvement ideas
•Implement changes
•Day 3
• “Continue “Try-storming improvement ideas
• Adjust strategy as required
• Implement changes
•Refine Improvement list/ideas
•Day 4
• Finalize improved methods
• Document current procedures and successes
• Demonstrate to other employees and refine ideas
•Day 5
•Complete documented procedures, Standard Work, measurements
• Determine long-term improvement plans priorities
•Read-out to Management
6
Current State
Page 1 of 3
46 tasks
30-60* mins
7
Current State
Distance Setup operator traveled:
Before 1972 Ft
8
Current State
Set-up current state time breakdown
%
5.5- 45 minutes**
Die Retrieval
- Wait time
- Load with Forklift
- Position
18%
12%
65%
5%
3.5 Minutes
Walking time
17 minutes
Clamp/unclamp
57%
25 %
- Moving bolts
- Locating bolts, washers, clamps
- Toe Clamp locate
Miscellaneous
13%
5%
- Clean, Ram adjusts, Ram lock, Dry cycle 3 times
4 minutes
30 - 69 minutes
** Forklift was immediately available; wait time ranges from 15-45 minutes
9
Current State
Targets of opportunity (for all dies) based on top five high volume
5.5- 45 minutes**
Die Retrieval
18%
65%
Problem: Variability in set-up time due to availability of Fork lift driver
Solution: Storage of dies at 200 ton press and use die tables (or
slide rails) to load dies as needed.
Benefit: Elimination of an average of 30 minutes wait time
17 minutes
Clamp/unclamp
57%
25 %
Problem: Wasted motion hunting, sorting, threading, screwing, aligning
Solution: “One-piece” clamps, standard base/top heights, fixed location,
standard work method
Benefit: Reduced wasted motion & time, small variation between
operators; Ripple effect on walking & Misc. time due to
standard work
10
Kaizen Newspaper-Phase 1
Item
Problem to be Resolved
1 Clamps not easy to use
Action Needed
Responsibility Date
Results
Make “one-piece” clamps
6/29
Complete
2
Walking by operator
Standard clamps/ 1-bolt
6-29
Complete
3
Different die bottom height
Cut bases to 2.5 inches
6-29
Complete
4
Different die top height
Cut top to 1-3/4 inches
5
No standard for number washers Make ½’ spacers
6-30
Complete
Remove t-handles and ignore
6-28
Complete
Footprint/Mount a Die stop
6-30
In-process
Orange line painted on crank
6-28
Complete
6-31
Complete
7/1
Complete
7/1
7/8
7/8
Complete
6 Locks on Ram don’t work
7
Die location in press is subjective
8 Bottom-dead center not easy to see
9 Screwing/unscrewing time on bolts Air ratchets both sides press
10 Over-torqued bolts
Torque wrench both sides
11 Air hose undersized/wrong location Change/add air hoses
12 New process is not documented Write new process& enter ISO
Material delivery system/location
13 Material not available to run
11
Kaizen Newspaper-Phase 2
Item
Problem to be Resolved
Action Needed
Responsibility Date
13 Wait time for Die delivery
Store dies behind machine
14 No standard for die location/position
Standard footprint dies by “family”
15 Continue to reduce set-up time
Use “Pit crew’
16 Quick set is for 200 ton only
Migrate process to 100 ton
17
Training plan and owner
Consistent training of operators
18 Measurement/audit of process
19 Use of clamps/bolts
Each shift report time-review GM weekly
Hydraulic clamping
20 TPM on machine
Oil leak fixed, stripped holes fixed
21 Non-standard die foot print
Standard future die design
Operator access to controls
22
23
Clamps may get used for wrong location
12
Add controls to back of machine
Color code edge top to match clamps
Results
7/15
Team in Action
13
Improvements
Press is not at lowest point (mis-aligned line on ram)
14
Improvements
WASTE
15
Not Needed!!!!
Improvements
Spacer, not washers
One bolt length
Multi-piece Clamp
16
One block size
One-piece Clamp
Improvements
5 Die numbers:
173
175
192
193
194
Pre-positioned die location
17
Improvements
Red-Top
Gray - Bottom
18
5S / Workplace Organization
Measures/Targets
Metrics
Beginning
State
(6/27)
Target
Goal
Travel Distance
2122 ft
350
200
23
15
(1972 operator
movement)
Number of
Elements/tasks
46
Minutes of
changeover time
60
27
10
Number of tools
required
16
8
6
19
Comments
Includes up and back
to the die rack
6/30
Status
450
29
Includes 30
minutes of
wait/delivery time
for Die via forklift
12
11