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Line 23 Problem

Solving Lean Kaizen Project

June 30th 2016

Deidre S. Whitfield

Line 23

Alloyd Automatic Heat Seal Machine

AADAutomotive Aftermarket Division

Line 23 Products:

20058

801

930 / 930C

901 / 901C

928 806 / 806C

907 / 907C / 907ES

280 / 280ES

913 / 913C

Problem Statement:

1. Completed Lean Training week ready to research and analyze all issues on the line

2. Improve and implement all new changes in order to reduce down-time by 75% and reduce labor revenue at a cost of $90,000 per year

3. Engaged the help and cooperation from Quality, Engineering, Supervisors, Supply Chain, Management, and Operators

LINE 23 DOWN-TIME

Method

Material Machine

Fishbone Diagram:

Print / Apply Labeler

2x4 / 6x4 Size ELC Labels

Small / Big Product Tubes

5 Different types of Boxes

Altering Label to meet current Packaging Specifications

Hand-Label / Date-Code / Apply Diamond (Product Specific)

Line Shuts Down for Labeling

Environment

PeopleMeasurement

Line runs only some shifts

Operators

Engineers

ELC Programmer

Extra Labor Hours in IMES

Additional Labor (Crew) Depending on Product

Line is used as a GO TO Line

2x2 Limited Quantity Diamond

Supervisors / Management

Corporate

Supply Chain

280 / 280ES ISSUES

Found huge down-time issues on one particular product Operators/Laborers shut down the line to re-apply Date-Code Operators/Laborers manually placed custom label(s) to outer

box during shut down

280 / 280ES Improvement Solutions

Get consensus to have Date-Code on inner product and outer boxes only

Modify outer box to have pre-printed DOT Symbols needed Updated all packaging standards to inform all operators and

laborers of new changes, and implementations

Box Optimization

Issues: 5 boxes

1 size tube in 3 different box sizes

Longer changeover time due to multiple RM changes

Box Optimization

Solutions:• Consolidate to 4 boxes

Streamline all big tubes to high volume box

Have all small tubes in same size box (Not 3 Different Boxes)

• Change label size to fix new box size

Box Labeling Project:Issue: • Operators/Laborers shut down line to hand

label some productsWhy?

• ELC labels not configured to:Print one at a timePrint on right size labelPrint orient upside down

Solution: • Create matrix of products and specs needed

• Contact Corporate ELC Support to fix issues

• Work with Lean Leads to verify implementation

Label Machine Programmed for PNO907

Graph Improvement:

• Tracked down-time relating to 280 / 280ES, Box and ELC Label issues for a total of 8 weeks

• During this tracking period, a totaled cost of $20,000 was due to these surrounding issues

Expected results after implementation:

• Reduce down-time by 75%

• Projected labor savings of $90,000 per year.

Final Summary280 / 280ES Improvement

Project:James MartinekBrenda Narcisse

Matt GaynerDeidre Whitfield

John Howell

Box Labeling Project:

James MartinekDeidre Whitfield

Matt GaynerRehan Khan

Courtlind Miller

Box Optimization Project:James MartinekPatricia Chee

Deidre WhitfieldCharles Hughes

Cross functional team across Operators, Supervisors, Engineers, Quality, and Supply Chain 1 Lean Kiazen event with 4 follow-up meetings with sub teams

Learned how to get buy-in from a variety of groups Tapped into Corporate’s resources for packaging and ELC changes

Operators are energized that we are eliminating extra work that appeared to have no benefit

3M Automotive Aftermarket Division

Questions?