Lean Article.Support Slides.

04/19/23 Fußzeile Slide 1

Slide 1. What We Have Done: People Involved

Area Manager Head of Logistics Executive Management

Head of Operations Plant Managers Executive Management

04/19/23 Fußzeile Slide 2

Slide 2. Type and frequency of customer demand and demand flow

Prep / Sort Customer and LifeGas Cylinders

Cylinders Filled

# of trucks arriving from customers

CustomerXX Cylinders

XX%

LifeGasXX Cylinders

XX%

CS

FS

PD

WE

O2 LIVXX Cylinders

XX%

Other GasesXX Cylinders

XX%

O2 LargeXX Cylinders

XX%

VGLsXX Cylinders

XX%

O2 Small Pin Index

XX CylindersXX%

X trucks per day

XX - XXX Cylinders

04/19/23 Fußzeile Slide 3

Slide 3. Current State:Step 3: Map the current value stream

Production Ticket Production Ticket

Delivery Ticket

CustomerDeliver from

Customer

Deliver toCustomer

IRange: 0 – 1400Avg.: 700

Loading8 FTEs

IRange: 0 – 1400Avg.: 700

Filling2.5 FTEs

IRange: 0 – 1400Avg.: 700

Prep2 FTEs

Office XXX

04/19/23 Fußzeile Slide 4

“Simplify” Create new plant flow and layout of facility

— Review the current state “spaghetti” diagram

— Assess where redundancy exists

— Eliminate excess distance traveled

— Reduce cross contamination of products where possible

— “poke-yoke” (mistake proof) where possible

— Standardize processes where possible

— Look for opportunities for visual management

22.04.2010 5

1

3

2

9

12

8

4

6

11

10

7

13

14

15

16

17

Cylinder Drop Off

Prep Area

Hydro

Bio-med - Dirty

Bio-med Clean

Technical Cabinet

Office Entry

Cylinder Staging

Full Cylinders

Full Other Gas Cyl

Cylinder Testing

VGL Filling

Large O2 Filling

Hydro Storage

Forklift

5 Filling

Medical excess

18 Nitrous Cage

19 Second Office

1S

3b2a

4

6S

5

9a

12

8a

11

10

7a

13

14a

15

16a

18

19

1 truck

1L

2b3a

7b

8b

8c

9b

9c8d

10

14b

15

16b

16c

17a

17b

17c

6L17d

Current State HoustonCurrent State Houston

75 ft 104 ft

108 ft

227 ft

120 ft105 ft

79 ft

196 ft

42 ft

53 ft

5 ft

135 ft

Empty

58 ft

88 ft

76 ft

108 ft

145 ft

Full

68 ft

21 ft

Retest

98 ft

72 ft

82 ft

88 ft

114 ft

79 ft

227 ft

201 ft

10 ft

10 ft

Slide 4. Current State Analysis and Future State Development

22.04.2010 18

1

3

2

9

12

8

4

6

11

10

7

13

14

15

16

17

Cylinder Drop Off

Prep Area

Hydro

Bio-med - Dirty

Bio-med Clean

Technical Cabinet

Office Entry

Cylinder Staging

Full Cylinders

Full Other Gas Cyl

Cylinder Testing

VGL Filling

Large O2 Filling

Hydro Storage

Forklift

5 Filling

Medical excess

18 Nitrous Cage

19 Second Office1 truck

Future State HoustonFuture State Houston

Full Full Spec Spec GasGas

HQAAHQAAHQAAHQAA

HQAAHQAA

HQAAHQAA

StageStage

Dri

ver

Lan

es

Dri

ver

Lan

es

Hyd

roH

yd

ro

Dri

ver

Dri

ver

Lan

es

Lan

es

Cu

st

Cu

st . .

Pic

kP

ick

Fu

ll M

H /

F

ull M

H /

Ass

et

Ass

et

Pre

pP

rep

Customer EmptyCustomer Empty

M / T / W / T / F / AssetM / T / W / T / F / Asset

AssetAsset

97 ft97 ft29 ft29 ft

16 ft16 ft

20 ft20 ft

20 ft20 ft

130 ft130 ft

5 ft5 ft

67 ft67 ft

45 ft45 ft

81 ft81 ft

130 ft130 ft

04/19/23 Fußzeile Slide 5

Sm

all

23

4 f

tSm

all

23

4 f

t

Larg

e 3

06

ft

Larg

e 3

06

ft

VG

L 2

27

ft

VG

L 2

27

ft

Texans

25% added to distance due to searching for cylinders since lack of order exists

25% added to distance due to searching for cylinders since lack of order exists

Slide 5. Measure Current Performance“Easy to Read Fashion”

Empty Small: 234Ft

Empty Large: 306Ft

Empty VGL: 227Ft

Full Small: 233FT

Full Large: 184FT

Full VGL: 227 FT

23

3ft

23

3ft

18

4ft

18

4ft

22

7ft

22

7ft

04/19/23 Fußzeile Slide 6

“5 Ys” 5Ys Overview

— Lincoln Memorial Story….

— Provide simple overview of why we will be asking so many questions of the employees

“Why 5S Is So Important” 5S Exercise

— Paper simulation searching for numbers while 5S is applied to the “workspace”

— Physically demonstrates to employees how 5S can reduce workload

— Sort / Set In Order / Shine / Standardize / Sustain

Slide 6. What We Have Done:Current State Assessment

Day 2 Day 3 Day 4 Day 5Day 1

04/19/23 Fußzeile Slide 7

Before

— Unorganized and lacking clear placement of product

— Excess inventory

— Management challenge

After

Slide 7. What We Have Accomplished:Before & After

04/19/23 Fußzeile Slide 8

Slide 8. Large Cylinder Storage

Before

— Lack of organization

After

— Color coded painting on floor for clear separation

— Installation of “visual” Kanban using floor coloring

04/19/23 Fußzeile Slide 9

Slide 9. What We Have Accomplished:Before & After

Before

— Drivers randomly dropping product where space is available

— Co-mingled Asset and Customer owned cylinders

After

— Create prioritization lanes for what to be filled next – visual management

— Separate Customer owned and Asset cylinders

— Add mural and signature board for commitment to the process