Kaizen Blitz: AR Room SMED Processes

Sally Ulman & Alan Magner

Monday 11th – 15th April, 2005

Contact:alanmagner@variancereduction.com

Kaizen Blitz MultiCoat Load Area

Team Members (l-r)

Sally Ulman

Josie

Anita

Lira

Alan Magner

George Webster

Ida

Justino

Julie

Event GoalsReduce Lead Time

Current Lead Time = 1099 minutes.Goal = 60 minutes (94% reduction)

Cycle TimeCurrent Cycle time = 863 secondsGoal = 777 seconds (10% reduction)

WIPCurrent WIP – 548 jobsGoal = 100 jobs (82% reduction)

Travelling DistanceCurrent = Poly – 13.8 metres, CR39 – 16.9 metres, CR39 + tint – 21.1

metresGoal = Poly – 7 metres, CR39 – 8.5 metres, CR39 + tint – 10 metres

Improve the appearance of the lineImprove the working conditions of the lineThese two items will go to improve morale and make the work area clean and safer

MultiCoat

Loading Area

Operation

Input Process Output Diagram

Outputs

Lead time (minutes)

Cycle time (seconds)

WIP (jobs)

Travelling distance

(metres)

Cell organization

(1-5)

Workflow from Grind

Methods & SOPs

Room Layout

Labour Utilization

Consumables &

Equipment (racks,

clips, wipes)

Inputs Goal

Leadership Support

We empower the team to make process improvements

Major changes will be reviewed and approved when possible

Time, resources and equipment will be provided

We hope most changes will occur DURING the event, all other action items will be given time to complete in the future

Kaizen Blitz Vision

Faster, Better, We Help People See.

Our aim for 2005 is to consistently deliver 48hr service to our Retail Customers from time of order to delivery back to store.

Sub Teams

Layout Team:

George, Lira, Julie - Layout

Alan, Anita, Josie – Repetitious work

5S, Visual Controls

Sally, Justino, Ida

Agenda

DATE TIME FRAME TIME AGENDA

Monday, 11-April-2005 9am - 5pm AM Leadership debrief, Goals, training

12:00 - 1:00pm PM Debrief & working lunch (Training Room)

1pm PM 5s/Visual Control Team: Action Items

Layout Team, Map Review, Repetitious work study

Tuesday, 12-April-2005 9am - 5pm AM 5s/Visual Control Team Action Items

Layout Team: options for new layout

Repetitious Team: Time observations, cycles of 7, options for best practices

12:00 - 1:00pm PM Debrief & working lunch (Training Room)

PM 5s/Visual Control Team Work Action Items

Layout Team: Determine best layout option

4pm Give a debrief to Leadership

Wednesday, 13-April-2005 12:00 - 5:00:pm PM Layout Team: Prepare for new layout

12:00 - 5:00:pm PM 5S Team: Complete action items at individual work stations

5:00 - 6:00 pm PM Debrief & working lunch (Training Room)

6:00pm - 12:00am PM All teams organise new layout and work stations

Thursday, 14-April-2005 6am - 9am AM Instruction on new layout from Layout Team Representative

10am - 12pm AM All Teams: Monitor & modify new layout

12:00 - 1:00pm Debrief & working lunch (Training Room)

1pm - 2pm PM 5S Team: Modifies workstations

1pm - 2pm PM Layout Team: Time new workflows

2-4pm PM Instruction on new layout from Layout Team Representative

4pm - 5pm PM 5S Team: Modifies workstations

4pm - 5pm PM Layout Team: Time new workflows

Friday, 15-April-2005 6am -6:30am AM Instruction on latest updates from Layout Team Representative

9am - 10:30am AM All Teams: Finalise presentation

10:30am AM Make presentation to Leadership

12pm PM Celebrate achievements & lunch at Lone Star

Layout Team

Team Members

George

Julie

Lira

Layout TeamRepetitious Work SOPs, New Layout

Draw up action items list

Revise existing flow map

New SOPs for repetitious work

Key aspects of new layout

Determine gaps in current system

New work process cycle times

New lead times with new layout

Potential Layouts, and prioritize selection

Objectives of Flow

Reduce work in progress (WIP)

Eliminate unnecessary travelling

Eliminate unneeded separation of work

Cost to Implement

Easier access to conveyors for loading staff

Allow for better flow of tinting jobs

Reduce lead time

Balance the line

Layout #1

Layout #2

Layout #3

Layout #4

Layout Design Matrix

Layout #1

Layout #2

Layout #3

Objectives of Layouts

3

1

2

3

1

4

1

2

4

4

3

13

4

1

1

3

2

3

4

1 19

22

16

Layout #42 2 4 2 4 2 3

2

3

1

4 23

The Kaizen voting results are listed above. It was felt that #2 and #4 were

tied. The management team voted to break the tie and #2 was chosen!

Current Layout

The Move

New Work Stations

Finalized Layout

Layout Team Achievements

Clearer lines for product flow

Improved visibility in department

Completed tint jobs flow to sorting

No more walking for loaders!!

Now have room to expand capacity

Visual controls for WIP using Kanbans

Lighting improved at workstations

Layout Team – Repetitious Work

Team Members

Alan

Josie

Anita

Repetitious Work – Layout Team

Every person had a different technique for

Wearing gloves or not

Cloths they were using

Lens cleaning and Loading

These were actioned itemed, as were;

Workflows with kanbans

Handling rejects

Error-proofing and timings

Different Wipes and Glove, No Glove

Glove, No Glove

New SOP on wearing gloves:

Team members on lens cleaning and lens loading to wear a pair of

Nitrile gloves – to protect wearer from sharp edges and exposure

to methnol, and to protect the lens from fingerprints and markings

Different Wipes

Different Wipes

Decided to use 1 type of cleaning cloth only – the Blue Chicopee

wipes. All white cloths were removed from all work areas.

An action item list is to test 4 possible cloths; based on

performance and cost.

Proper Cleaning Methods

Correct gloves and cleaning towel

Work Stations Before

WIP Removed

Work In Progress before, later the work was processed and many of

the racks were removed for the final layout

Old way of Loading of #3 Jobs - CR

Proper Loading of #8 Jobs

The first space

is empty

All clip hangers

are correctly in

the grove above

The #8 clip

is used

Equal spacing can be seen on the

bottom at each clip

Proper Loading of #9 Jobs

Process Book Number

Process Book Number

Completed Process Book Number

How Racks Might Come from Cleaning Area

Here, the clips are in the closed

position. Having them like this

will prevent them getting hooked up

Here, the clips are in the open

position, the arms can get tangled

when removing them to load the

clip.

Jig or No Jig, That is the QuestionIn January the jig was used by most people. Notice the failure rate downstream in sample one of Test of Proportions (n1).

In April, very few used the jig. Notice the failure rate downstream in sample one of Test of Proportions (n2).

Conclusion: using the jig does not appear to have an impact on downstream failures.But ….. Does the jig reduce cycle time?

User defined parameters

Number Defective Group #1 (x1) 55

Size of Sample #1 (n1) 8500

Number Defective Group #2 (x2) 52

Size of Sample #2 (n2) 9500

Proportion Sample #1 (p1) 0.00647

Proportion Sample #2 (p2) 0.00547

p-value 0.38506

Test of Proportions

Results

SPC XL is Copyright (C) 1999 Digital Computations, Inc. and Air Academy

Associates, LLC. All Rights Reserved. Unauthorized duplication prohibited by

law.

Jig Test – 12 Lenses in Each Test

Jig Use Finding:

Cycle Time = 1:57

Rework = 0

Observations:

• Good

• Less likely to scratch lens

• Sat securely

• Did not look hard to do

No Jig Use Findings:

Cycle Time = 1:16

Rework = 1

Observations:

• Ida had a great technique

• Looks more difficult to new workers, both to do and in scratching lens

• Might be tilted

Final Decision: Jig. We will adopt an SOP that address the non-jig people

To make using the jig the best it can be.

Proper Jig Use

Proper use of the jig

Note how long the clip goes down into the jig

The clip arms are in the wheels each side of the jig

The arms will open and the lens can be easily placed in the correct position

Proper Loading of Clip on Jig

Sometimes loaders would allow

The clip arms to twist when loading

Clip arm has

to be is the

groove of the

wheel

If the clip arms are flat

against the back of the jig

the arms WILL go in

the wheel groves

Error Proofing of Jig

Adding a space on the top of the jig

allows for the top of the clip to be

braced during the loading of the clip

The side view shows the thickness

of this spacer.

Another Error Proofing of the Jig

To ensure the proper placement of a FT in the clip, lines were drawn on the jig.

If the operator lines up the top of the FT to the lines, either over them or parallel to them, it will be at the correct 300 angle

Proper Loading of Lenses on Holders

To load property

the narrow end of

uneven lenses need

to be on the bottom, the

wide area on the side

65 and CR Clips

Clip used to 65 size lenses.

Note the Yellow Color at top

Clip for CR, note the blue color at

the top

Poly Clip

This is a Poly Clip

Note there is no color at the top of the clip.

5S / Visual Controls Team

Team Members:

Sally

Ida

Justino

5S, Visual Controls

Action items list

Before and After pictures

Goals of the group

Determine gaps in current system

5S, Visual Controls Goals

To set the standard for workplace organisation

Implement procedures to ensure consistency

Positively effecting workplace safety, product quality, production cycle times and capacity

Supporting Visual Factory Management will develop the model cell for the rest of the plant to benchmark

All this will be achieved by using the most simplistic methods possible interviewing all involved in the set-up and ultimate decisions.

5S, Visual Controls Team Action Items

Kaizen Blitz – Action Item – Multicoat 5S Team Number Priority

#

Problem/Need Solution/Action Person

Responsible

Date

Due

Date

Done

1. Incoming lenses on floor, no clear

marking where they should be

Set in order – mark it. Justino 15

April

13

April

2. Scanner and mouse in incoming area, no

home

Set in order – mark it Justino 15

April

13

April

3. Scan cards not colour coded for type Colour code Ida 30

April

4. No area for scanned item Set in order – mark it Justino 15

April

13

April

5. Lack of organization of yellow cleaning

area

5S the area Ida – moved to

grind dept

15

April

13

April

6. No clear direction of where trays go Flow pattern with arrows are needed Justino 15

April

13

April

7. Lack of organization in cabinet under

yellow marking area

5S the area Ida 15

April

13

April

8. Lack of organization of the equipment

and materials in the tinting area

5S Ida 15

April

13

April

9. Bad access for loaders to get jobs Better layout to minimize motion

and transportation

Justino 15

April

13

April

10. Load bench disorganized. No set

standard

Set in order – 5S Justino 15

April

13

April

11. Disorganized supervisors office and

MSDS binder area

Set in order, 5S Justino 15

May

13

April

12. Loading scanner, no easy access Better layout Ida – Layout

Team

15

April

14

April

13. Storage area shelving is large and has

wrong labels – they are outdated

Decide needed space requirements,

Set in order – 5S

Ida 15

April

13

April

14. Mouse and scanner at load area has no

real home

Needs a home – layout and 5S Ida - Layout 15

April

14

April

15. After loading, no clear direction to

conveyor

Flow pattern with arrows are needed Justino 15

April

13

April

16. Notice board is outdated Determine what items are needed on

the board and place it is an area

where it will be seen.

Ida 15

April

14

April

17. Clean holders are not easily accessible

and are just dumped into the bins

Find a good place for them, store

them in a better orientation for

loading – develop best method

Ida 30

April

18. Lack of posted, visual SOPs in loading

area

Develop SOPs with visual controls

shown

Justino 15

April

13

April

19. Lack of posted, visual SOPs in tinting

area

Develop SOPs with visual controls

shown

Ida 15

April

13

April

20. SOPs in incoming sort area need to be

placed on top of rack

Get holders that grind uses to place

them in

Justino 20

April

21. Extra clips when holder racks are not

full have no home at the loading station

Need a home, set up a bin and

location

Ida 14

April

14

April

22. No home for rejects at loading station Need a home, set up a bin and

location

Justino 14

April

14

April

23. No home for 65 clips at the loader

station

Need a home, set up a bin and

location

Ida 14

April

14

April

24. Trash cans under cleaning area are

unstable

Get engr to secure better and a better

spacer

Justino 14

April

14

April

25. No stapler at the sorting table Find a stapler and a home for one at

the sorting table

Ida 14

April

14

April

26.

5S, Visual Controls Team Action Items

Incoming AreaBefore Picture

Work on the floor, tripping hazard,

too much WIP.

After Picture

Limited amount of work is stored

in the incoming racks, all are sorted

before going to the loaders

Dipping Waste and Throughput Board

Before Picture After Picture, this is located in an

area better seen by the workers

Boards in the Area

Before Picture

Clutter on boards. Not standardized. Needs to be In the best place for all to see.

5S the boards, place in a good spot with just the info we need on it.

The Area has Signage with Clear Goals for All Involved

You are entering a Set – In – Order Zone Area Goals

Yellow Line Removal

Before:Small area to work, items for process

have no clear home

SOPs covered

by all the WIP!

Inlet Rack to Load Area

Before Picture

Too much WIP, not clear on prioritized

work, flow is impeded, difficult for loaders

to access.

The New Layout has a Major Reduction of WIP

Only this side of

the inlet trays have

lenses, the other

side are empty trays

for recycle to grind

A small number

of lenses will be

in queue in tinting

A limit of 6

trays are to be

at each of the 2

stations.

Tint Area - Before

Before Picture

No clear direction

of flow, too much

stuff, disorganized

stuff on the floor,

no clear SOPs.

Tint Area After

Tint Samples

Before - these racks were in the wrong

order, could fall down, and added

clutter to the area

After - the racks are numbered, in the

Right order and mounted In the packets

they came in.

Misc. Stuff Before

Before Picture

Inconsistency in where items are placed.

Need 5S!

Load Work Station at Shift Start -Before

Before Picture

Inconsistency in the work stations. They look really clean at the start of

Each shift, but take on a different look when works starts. Need to perform

5S and standardized work station layout and procedures.

Two Different Work Stations

Load Area

Materials used at Cleaner and Loading Station

Methanol and wipes for cleaning Rack tags and rubber bands to tie

up the grind cards

Load Station Before

Methanol container is to the upper

left and operator is right handed,

this increases the stretch.

Before Picture

This work station looks different from

others. Need 5S and standardized

work stations.

Load Station Before and After

Before Picture

Jig is not used in this work station

This workstation

looks different from

others. Need 5S

and standardized

stations.

After Picture

All items in the station are used on

a daily basis, are in places designed

by line workers

Loading Scanner Location

Before Picture

No place for the scanner and mouse, no table to place products to scan them

AND see the monitor at the same time.

Handling rejectsNo clear

procedure for

dealing with

lenses that have

scratches:

Most people

place in a

tray, the under

the desk, and

chase Supervisor

for a 2nd opinion

Now have a

central point for

any defect lenses

found at loading

– Supervisor

knows where to

look for any

problem jobs

Before Picture After Picture

Clips / Lens Holders

Before Picture

Different holder types Holders are stored in a haphazard

manner from cleaning process in

the bins

Materials Storage Area

Before Picture

Holder bins and marks in the storage cabinet. Needs 5S and visual controls

that can be seen and used.

Supervisor Station

Before Picture

Supervisors station is full of clutter and easy access to the MSDS books.

Area needs to have 5S done and only the items needed in the area.

Supervisor Station After

Justino is performing 5S in the desk

Area, making a place for everything.

Final work, everything here is NEEDED.

has a home and is in it’s home.

Conveyor and Extra Storage

Before Picture

Remove the

board where it

is needed, if

it is needed. Might

use just the SOPs

on the board.

Extra storage area might need to be moved

or removed. 5S will sort this item, placing

it in the Red Ticket area, if layout wants it,

we can bring it back.

Marking the Conveyor

Before, it was not clear where to place

racks on the conveyor.

After, the GREEN area shows where

The racks are to be placed.

Cleaning of lensesSOPs not given importance in old

layout

In new layout SOPs are given more

visibility

Workflow is now obvious

No clear workflow, lots of unnecessary

motion

New SOPs use as little motion as

possible, influencing the new desk

layout

Set up Kanbans for all workflow

Em

pty

trays

CR

39

Poly

Set up Kanban

of 6 trays for

Grind to

Multicoat job

sorting

Set up Kanban

of 3 trays from

Job sorting to

loading

Set up a “Pick

me Next”

identifier to

preserve FIFO

workflow

New 1-page photo-rich SOPs

Kaizen AchievementsReduce Lead Time

Past state Lead Time = 1099 minutes.Goal = 60 minutes (94% reduction)Achieved = 131 minutes (88.1% reduction)

Cycle TimePast state Cycle time = 863 secondsGoal = 777 seconds (10% reduction)Achieved = 538 seconds (37.7% reduction)

WIP Past state WIP – 548 jobsGoal = 100 jobs (82% reduction)Achieved = 269 jobs (50.9% reduction)

Travelling DistancePast state = Poly – 13.8 metres, CR39 – 16.9 metres, CR39 + tint – 21.1

metresGoal = Poly – 7 metres, CR39 – 8.5 metres, CR39 + tint – 10 metresAchieved = Poly – 11.8 metres, CR39 – 11.4 metres, CR39 + tint –

16.6 metresImprovement = Poly 14.5% CR39 32.5% CR39 + tint 21.3%

How the Kaizen Team Feels Sustainability will be Accomplished

Communicate with members consistently

Positive encouragement

Lead by example

Keep explaining!

Collect feedback – promise to review in 2 weeks time (allow time for acceptance)

Spot checks! – by the Supervisor

1-to-1 training on new technique; for the first week, give refresher training daily

Next Steps – Wish List

Place two more tables in the loading area, making it possible to add 2 people to the area to process more product, IF NEEDED

Extend the conveyor down to the 2 new tables

5S the cleaning of clips area since our work cell members work in their as well – another Kaizen might be needed to do this

Install an LCD display board for Lenses per hour per person

This Says It All