lecture 7b

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KATA © 2016 The Leadership Network ® © 2016 Jidoka ® 01 Storyboard and Kata forms to supplement the Coaching Scripts 1. Learner’s Story Board, slides are 36” x 48“, Landscape 2. All other forms are 8.5”x11”, OR 11” X17” Landscape Supplement Lecture 7b Rev. 09.21.2016

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Page 1: Lecture 7b

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

Page 2: Lecture 7b

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

Page 3: Lecture 7b

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

Page 4: Lecture 7b

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

Page 5: Lecture 7b

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

Page 6: Lecture 7b

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

Page 7: Lecture 7b

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

Page 8: Lecture 7b

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

Page 9: Lecture 7b

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

Page 10: Lecture 7b

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

Page 11: Lecture 7b

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

Page 12: Lecture 7b

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”

Page 13: Lecture 7b

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”

Page 14: Lecture 7b

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”

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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”

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© 2016 Jidoka®

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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”

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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”

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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”

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© 2016 Jidoka®

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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”

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© 2016 Jidoka®

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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”

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© 2016 Jidoka®

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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”

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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

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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

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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:

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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%

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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?