lecture 7b
TRANSCRIPT
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
01
StoryboardandKataformstosupplementtheCoachingScripts
1. Learner’sStoryBoard,slidesare 36”x48“,Landscape
2. Allotherformsare8.5”x11”,OR11”X17”Landscape
SupplementLecture7bRev.09.21.2016
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
02
FocusProcess: Challenge:
TargetConditionAchieveby:06.10.2016
CurrentCondition
ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertime
ProcessMetrics ProcessMetrics
OutcomeMetrics
OutcomeMetrics
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
ACMEMachiningCell
FirstPassYield> 98%MillReliability> 90%
PPLH> 50Scrap< 3.5%Overtime=0%
Scene1Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
03
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FirstPassYield> 95%MillReliability> 85%
PPLH> 37.5Scrap< 5%Overtime<10%
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene2Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
04
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FirstPassYield> 95%MillReliability> 85%
PPLH> 37.5Scrap< 5%Overtime<10%
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene3Script
Obstacle
1
2
3
4
5
Workload on operators
Scrap
OBSTACLESPARKINGLOTHowwillyoumeasurethat?
Less number of Hobs
Less number of Turning Mills
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
05
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#0-Slide13
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FirstPassYield> 95%MillReliability> 85%
PPLH> 37.5Scrap< 5%Overtime<10%
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene4Script
Fi.5
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
06
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#1-Slide14
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene5Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
07
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#2-Slide15
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
PDCA#3-Slide16
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene6Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
08
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#2-Slide15
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
PDCA#4-Slide17
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene7Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
09
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#5-Slide19
PDCA#4- Slide18
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene8Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
10
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#6-Slide20
PDCA#4– Slide18
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene9Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
11
TargetConditionAchieveby:06.10.2016
CurrentCondition
ProcessMetrics ProcessMetrics
OutcomeMetrics OutcomeMetrics
PDCA#6-Slide21
PDCA#7– Slide22
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell
Scene10Script
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
12
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time
ProcessMetric:Number of Hob machines operating
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-26-16
Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order. And I want to get an estimate of when they will be ready to test the two Hob machines that are down.
I expect to learn that we have been waiting for parts and to learn when machines will be ready to test
TIME:11:00 AM
“GoSee” X“Exploratory”
“Hypothesis”
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
13
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time
ProcessMetric:Number of Hob machines operating
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-26-16
Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order and estimate of when they will be ready to test the two Hob machines that are down.
I expect to learn that we have been waiting for parts and to learn when machines will be ready to test
TIME:11:00 AM
“GoSee” X“Exploratory”
“Hypothesis”
DATE:5-27-16
I will collect all hourly computer reports from each Hob on first and second shift and compare them looking for any changes in quality standards. I will track how many cycles of the machines to see if they fail before the end of a 50 piece sample run on this shift.
I will learn how many Hobs can run qualitypieces consistently and if we need to shorten number of cycles between shifts.TIME:
10:30 AM
“GoSee” x“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
14
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 05-26-16 Process: Hob Machining of gear
Obstacle: Don’t know what it will take to get 10 Hobs running while maintain quality at 7 min cycle time
ProcessMetric:Number of Hob machines operating
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-26-16
Talk with setup and maintenance to see the status of the machines that have been down longest to see if we are waiting on parts to be made or on order and estimate of when they will be ready to test the two Hob machines that are down.
I expect to learn that we have been waiting for parts and to learn when machines will be ready to test
TIME:11:00 AM
“GoSee” X“Exploratory”
“Hypothesis”
DATE:5-27-16
I will collect all hourly Gleason reports from each Hob on first and second shift and compare them looking for any changes in quality standards. I will track how many cycles of the machines to see if they fail before the end of a 50 piece sample run on this shift.
I will learn how many Hobs can run qualitypieces consistently and if we need to shorten number of cycles between shifts.
10 out of 18 machines we started with on 5-27-16 all are still running quality pieces after an average of fifty cycles, and 50 quality parts have been produced. I wanted to put all ten Hobs through a complete 8 hour shift, however, we are waiting on two out of the ten Hobs to be fixed for production.
That we have 10 out of 18 machines that are consistently running quality pieces
If I had the opportunity to conduct this PDCA again, I wouldn't do anything differently.
I learned we have enough Hobs running to meet goal of 2200 pieces per shift.
TIME:10:30 AM
“GoSee” x“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
15
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Save time checking pieces
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-31-16
Work with operators to find the best place for second check station at end of lineTo help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts
I expect to find a place to set up at second check station.It will help reduce time walking back and forth to check parts.TIME:
11:00 AM
“GoSee”
“Exploratory” X
“Hypothesis”
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
16
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Save time checking pieces
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-31-16
Work with operators to find the best place for second check station at end of lineTo help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts
I expect to find a place to set up at second check station.It will help reduce time walking back and forth to check parts.
It took an average of ten seconds longer to check parts at the table in between Hobs than the table in middle of line. We have enough gages on line for both sides of line. Run-out is an hourly check that is charted.
I learned that a table at middle of line would be better and that we have enough gages on the line.
If I had to do this over again, I would have tried to find a table for the center of line
In my next PDCA, I will set a table up and start working on finding the most efficient place for checking part quality.
TIME:11:00 AM
“GoSee” X“Exploratory”
“Hypothesis”
DATE:6-01-16
Set up a quality check station at the head of the line. Have each operator run five machines and collect data. We will record the number of pieces produced and how many hob adjustments, are needed for part quality.
We will test this with 1 operator on second shift and 2 operators on first shift for two hours
I expect to learn the average parts that an operator can run on five machines and the amount of time spent making adjustmentsTIME:
11:00 AM
“GoSee”
“Exploratory” X“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
17
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 5-31-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Save time checking pieces
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:5-31-16
Work with operators to find the best place for second check station at end of lineTo help reduce the time for checking pieces, and see if we need more gages and record the time walking to check parts
I expect to find a place to set up at second check station.It will help reduce time walking back and forth to check parts.
It took an average of ten seconds longer to check parts at the table in between Hobs than the table in middle of line. We have enough gages on line for both sides of line. Run-out is an hourly check that is charted.
I learned that a table at middle of line would be better and that we have enough gages on the line.
If I had to do this over again, I would have tried to find a table for the center of line
In my next PDCA, I will set a table up and start working on finding the most efficient place for checking part quality.
TIME:11:00 AM
“GoSee” X“Exploratory”
“Hypothesis”
DATE:6-01-16
Set up a quality check station at the head of the line. Have each operator run five machines and collect data. We will record the number of pieces produced and how many hob adjustments, are needed for part quality.
We will test this with 1 operator on second shift and 2 operators on first shift for two hours
I expect to learn the avg parts that an operator can run on 5 machines and the amount of time spent making adjustments. I am unsure if we can produce 500 quality parts over a 2 hour period, which is what is necessary to cover the customer demand for production I expect Charles on 1st
shift will produce more parts than James on 2nd
shift due to training Jennifer, new operator
The operator averaged 413 over two hours.Charles produced 350James produced 583Jennifer produced 308 (in training).
So, James on 2nd shift actually produced more that Charles on first shift, even though he was training Jennifer as well as running his own production requirements. This was an unexpected surprise.
It was reported that it is possible to run over 500 parts in two hours.I will talk with James to see if he ran any differently than Charles or Jennifer.When all machines are available to run I don’t believe it will be a problem to reach desired number of 500 quality parts produced over a two hour period. We should be able to revise the standard work to match James’ best practice.
TIME:11:00 AM
“GoSee”
“Exploratory” X“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
18
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Shared labor Hob/shape
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
DATE:6-02-16
Have the first operatorwork at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift.
The first operator will then move to Shaper cell for the remainder of shift
I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should increase output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH)
TIME:2:00
“GoSee”
“Exploratory” X“Hypothesis”
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
19
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Shared labor Hob/shape
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:6-02-16
Have the first operatorwork at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift.
The first operator will then move to Shaper cell for the remainder of shift
I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should increase output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH)
Operator 1 ran 380 parts at the Hobs for the first 2.5 hours running six Hob machinesHe ran 394 at the Shaper machine in 5 hours running 4 shaper machines
I learned that reaching 500 at Hobs in 2.5 hours is possible. The operator is a new employee (less than 90 days) and should get faster with more time, training and experience.If six Shaper machines are running getting 600 in 5.5 hours, then it should be easy for the Shaper machines to average 20 parts per hour per machine
TIME:2:00
“GoSee”
“Exploratory” X“Hypothesis”
DATE:6-03-16
I plan to have 1 operator on first shift run a layout of 6 Hobsinline with check station at both ends of the line. I will compare this to a layout of 6 Hobs in a U-shape cell to see if this is an advantage to running with the U-shaped cell layout and the two check stations.
I expect there will not be a advantage running U-shaped for six hours a day after time spent adjusting machines and quality checking the first pieces. TIME:
11:00
“GoSee”
“Exploratory” X“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
20
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: 6-02-16 Process: Hob Machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Shared labor Hob/shape
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:6-02-16
Have the first operatorwork at four of the Hob machines for 2.5 hours of the shift and a second operator run six Hob machines for 8 hour shift.
The first operator will then move to Shaper cell for the remainder of shift
I expect to run between 400-500 parts at the Hob the first 2.5 hours and 500 to 600 pieces at the six shapers for the remainder of shift It should boost output at audit. This will help our productivity measure of Parts Per Labor hour (PPLH)
Operator 1 ran 380 parts at the Hobs for the first 2.5 hours running six Hob machinesHe ran 394 at the Shaper machine in 5 hours running 4 shaper machines
I learned that reaching 500 at Hobs in 2.5 hours is possible. The operator is a new employee (less than 90 days) and should get faster with more time, training and experience.If six Shaper machines are running getting 600 in 5.5 hours, then it should be easy for the Shaper machines to average 20 parts per hour per machine
TIME:2:00
“GoSee”
“Exploratory” X“Hypothesis”
DATE:6-03-16
I plan to have 1 operator on first shift run a layout of 6 Hobsinline with check station at both ends of the line. I will compare this to a layout of 6 Hobs in a U-shape cell to see if this is an advantage to running with the U-shaped cell layout and the two check stations.
I expect there will not be an advantage running U-shaped for six hours a day after time spent adjusting machines and quality checking the first pieces.
The operator ran 1344 parts with the Hob machine running inline. The operator produced 1837 running in a U-shaped cell. Operator said that he must cold start every machine now that there isn’t a third shift. Running warm up cycles and one piece load to check size and make adjustment. He ran 84 for his first hour. He also had machine down waiting for Hob to be sharpened He ran machines in another line.
I learned that the U-shaped cell layout produced over 500 additional parts. However, we are losingproduction because of cold start up with no parts in que as we had running 3 shifts. I learned that running the machines in straight line didn’t produce as many parts as the U-shaped cell on first shift.
TIME:11:00
“GoSee”
“Exploratory” X“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
21
KATAPDCACYCLESRECORD (each row=oneexperiment)Date:6-6-16 Process:Hob machining of gears
Obstacle: We don’t know how the operators will cover work load going from 3 shifts to 2 shifts
ProcessMetric: Straight line verses U-shaped cell
Learner: Terry Coach:John
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened?(observe)
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:6-6-16
I plan to have an operator on second shift run a straight inline layout of the 6 Hobs with check station at both ends of Hob line. We will leave al parts in que from first shift.I want to see how many parts are gained in comparison to the cold starting without parts in que. There should not be the down time waiting on the first piece at packaging
I expect that the inline layout without the delay from the cold startup will produce the same production output numbers. I expect this will be closer to the same production as running the U-shaped cell.
TIME:11:00
“GoSee” X“Exploratory”
“Hypothesis”
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
22
1
2
3
4
Wehave1,000pcsininventoryatthestartoftheline;allothermachinesproduceinflow
Wecheckqualityaccordingtoasamplingplaanof6partsevery15minutes.
We100%finalauditpercustomercontractrequirementsatpack.
BLOCKDIAGRAM
OBSERVATIONS
1,000pcs
DuetodiminishingproductionvolumewehaveexesscapacityinourHobMachinesandTurningMills.
CONDITIONCURRENTHOB1 HOB2 HOB3 HOB4 HOB5 HOB6 HOB7 HOB8 HOB9
HOB10 HOB11 HOB12 HOB13 HOB14 HOB15 HOB16 HOB17 HOB18
Shaper1
Shaper2
Shaper3
Shaper4
Shaper5
Shaper6
CNCMachine1
CNCMachine2
TurningMill1
TurningMill2
TurningMill3
TurningMill4
FinalAuditandPAck
IQA
TurningMill5
TurningMill7
TurningMill6
TurningMill8
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
23
1
2
3
4
1,000pcs
BLOCKDIAGRAM
OBSERVATIONS
CONDITIONTARGETHOB1 HOB2 HOB3 HOB4 HOB5
HOB6 HOB7 HOB8 HOB9 HOB10
Shaper1
Shaper2
Shaper3
Shaper4
Shaper5
Shaper6
CNCMachine1
CNCMachine2
TurningMill1
TurningMill2
TurningMill3
TurningMill4
FinalAuditandPAck
IQA
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
24
F/A-Pack
Mill8
Mill7
Mill6
Mill5
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob18
Hob17
Hob16
Hob15
Hob14
Hob13
Hob12
Hob11
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OTHERPROCESSMETRICS:
MillReliabilityis80%
OvertimeisduetomachinereliabilityatTurningMills1,7,&8
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
Wehaveexcesscapacityandhighvariationinmachinecycle
withourHobMachines.Hob18cycletimeexceedsTaktTime
Wehaveexcesscapacityandhighvariationinmachinecycle
withourTurningMillMachines.
PPLH=27.5
Scrap=6.7%
OverTime=8%
FirstPassYield=93%
ExitCycleVar(Pack)=10s+/-12%
Hob18LowestRepeatable HiVar=+195%
LoVar=-24%=14seconds
TaktTime=12.3seconds
PlannedCycleTime=10.5Seconds
NumberofShifts=3
NumberofOperators=10
CURRENTCONDITIONSUMMARYSHEET
OutcomeMetrics(SeeCharts)
ProcessStability:
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
25
F/A-Pack
Mill4
Mill3
Mill2
Mill1
CNC2
CNC1
Shaper6
Shaper5
Shaper4
Shaper3
Shaper2
Shaper1
Hob10
Hob9
Hob8
Hob7
Hob6
Hob5
Hob4
Hob3
Hob2
Hob1
Hob0
Hob1
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
OutcomeMetrics(SeeCharts)
ProcessStability:
MillReliabilityis90%
TARGETCONDITIONSUMMARYSHEET
Machinecycleandcapacityisbalancedawith10Hobs
NoneoftheHobcycletimesexceedTaktTime
Machinecycleandcapacityisbalancedawith4TurningMills
NumberofOperators=10
NumberofShifts=3
OverTime=10%
PlannedCycleTime=10.5Seconds
NOTESANDOBSERVATIONS
PROCESSCHARACTERISTICS:
OTHERPROCESSMETRICS:
TaktTime=12.3seconds
HobLowestRepeatable
=10seconds
ExitCycleVar(Pack)=10s+/-10%
HiVar=+15%
LoVar=-15%
FirstPassYield=96%
PPLH=37.5
Scrap=5.0%
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
26
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
27
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
28
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
29
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
30
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
31
KATA
© 2016 The Leadership Network®
© 2016 Jidoka®
32
KATAPDCACYCLESRECORD (each row=oneexperiment)Date: Process:
Obstacle: ProcessMetric:
Learner: Coach:
Date, Time,Type,Step &Metric Whatdoyouexpect?
CoachingCy
cle
Experim
ent
Whathappened (observeclosely)?
Whatdidyoulearn?(what youexpected?/whathappened?)
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
DATE:
TIME:
“GoSee”
“Exploratory”
“Hypothesis”
SPECIFICDETAILSOFTHESTEP
SPECIFICDETAILSOFHOWITWILLBEMEASURED
DOESTHISSTEPBUILDFROMTHEPREVIOUS
PDCA?
MAKEAPREDICTION
IFINTRODUCINGACHANGE,WHATIMPACT
WILLITHAVEONMETRICS?
FACTSANDDATAHERE
ABOUTTHEPROCESS?
ABOUTSCIENTIFICPROBLEMSOLVING?
IFYOUWEREDOINGTHISPDCAAGAIN,WHATWOULD
YOUDODIFFERENTLY?
HOWWILLTHISIMPACTYOURNEXTPDCA?
SPECIFICDETAILSOFTHESTEP
SPECIFICDETAILSOFHOWITWILLBEMEASURED
DOESTHISSTEPBUILDFROMTHEPREVIOUS
PDCA?
MAKEAPREDICTION
IFINTRODUCINGACHANGE,WHATIMPACT
WILLITHAVEONMETRICS?
FACTSANDDATAHERE
ABOUTTHEPROCESS?
ABOUTSCIENTIFICPROBLEMSOLVING?
IFYOUWEREDOINGTHISPDCAAGAIN,WHATWOULD
YOUDODIFFERENTLY?
HOWWILLTHISIMPACTYOURNEXTPDCA?