Download - A3 CI 1000 5S Kaizen v2
Atlanta Beverage Folding Carton Facility
CI 1100 5s Fall 2013
Initial Conditions
Disorganized and cluttered workspace.
Unnecessary movement of aniloxes.
Lack of anilox cleaning and standardization;
resulting in product defects.
Excessive storage space and inventory of unused
plate sleeves.
Excessive motion necessary to move equipment
press-side.
Team Members
Frank Humphries Line Lead Georgia Stephens Pre make ready specialist
Rodney Lomax Shift Lead Quinton Jones Pre make ready specialist
Michael March Operator Johnnie Robinson Operator
Shawn Gregory
Co-op student engineer
Improvement Opportunities Identified by Team
Tasks were divded into four
disciplines: general, anilox, mandrel, and
plates.
Each discipline had a procession of
events based on priority and prerequisit
actions.
Much of the work focused on
improving the transportation and maintenance
of aniloxes and sleeves.
It was proposed to rearrange large
capitol items in order to increase workplace
flow.
Work on project when not making the
line ready or firefighting down time.
Accomplishments
Sorted, Set, Shined, and standardized mobile Doctor
Blade, Deck Rebuild, and everyday tool carts.
Standardized PM tool box, mounted on castors for
press side use.
Created Anicam station and SOP on anicam.
Standardized anilox tracking document and forecaster.
Trained operators on anicam data documentation.
Mobile plate sleeve carts
Cleaned press side table and created die and delivery
tool area
Results
Potential is in place for paperboard waste
reduction via cleaner aniloxes once washer is moved
in January. Also, excessive anilox transportation
will be cut.
Mobilizing carts and tools have played a role
in decreasing average operational downtime and
make ready times.
All aniloxes are inventoried by serial
number, original BCM and LPI, and will be updated with a current BCM count.
Future Actions
Begin to phase out old and damaged mandrels, plate
sleeves, and aniloxes.
After washer is installed, have washer modified to
hold aniloxes with caps, and paint caps according to
BCM.
Remove old racks.
Have anilox racks cut so they become mobile.
Work excessively with new plate mounter so removal
of old mounter is expedited.
Build or purchase press side container for cook kit.
Anilox Pores
Figures 1 & 2: Spaghetti diagrams show the reduction of transportation waste associated with adding and removing aniloxes from the press. Batch removal and instillation are now
possible due to the condensed anilox maintenance station and modified transportation rack.
Figures 3 & 4: Cart used to change doctor blades is now standardized with a prescribed list of tools and parts.
Figures 5 & 6: Tool box used for non-PM downtime was cleaned and removed of excess clutter. Box was placed on castors to reduce excess transportation and facilitate quicker
repairs.
Figures 7 & 8: Table top for data recording and tooling was cleaned and standardized.