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MILLSHOP MOULDER SET UP REDUCTION

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Presentation Outline

1. Company Background

2. Problem Selection

3. Team Composition

4. Objectives & Approach

5. Current Conditions

6. Cause Investigation

7. Counter Measures

8. Results

9. Follow-up Plan

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COMPANY BACKGROUND

• Privately held company, headquartered in Steinbach, MB

• Canada’s largest wood window and door manufacturer

• Supplier to Canada, United States, and some international markets

• One of southeastern Manitoba’s largest employers and have been since the 1960s

• Manufacturing performed in one facility (600,000 sq ft)

Problem Selection

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• Focus: reduce set up time on moulder 260, to increase # of set ups per day

• Rational: set ups are very manual and take a long time

• Expected benefits: reduction in set up time to increase number of set ups from 8/day to 10/day

Team Composition

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• Kaizen Team-Neta (leader)-Elise (day process owner)-Shaylin (eve process owner)-Theo (moulder assistant)-Anna (outside eyes)-Mercedes (Manufacturing Engineer)-JL (maintenance)

• Team Support-Alexander (kaizen sponsor)-Warren (facilitator)

Objectives & Approach

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• Objective: to reduce set up times on our longest set up process by 30%

• Approach: 3 day Kaizen Blitz

Kaizen Steps:

1. Training

2. Analyze current set up process

• Observe process and value stream map

3. Separate internal/external activities

4. Convert as many internal activities as possible to external activities

5. Optimize internal activities

6. Optimize external activities

7. Measure impact of set up reduction

Current Conditions

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Observations:

-manual set ups and adjustments

operator 1: 2002 steps operator 2: 1000 steps

total astragal set up time: 58 minutes

Cause Investigation

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Root Causes:

-Manual labour intensive set ups-Extra motion due to location of tools-Manual calculations-Waiting due to sharing tools

Counter Measures

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-Total ideas = 34-Total implemented = 21

-3 ideas tested but not successful

-71% of ideas were implemented-62% were successful

Counter Measures – MANUAL SET UP

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Counter MeasureUsing a drill to remove wheels

CauseUsing allen key to remove wheels

EffectTime consuming and manual

BEFORE AFTER

Counter Measures – EXTRA MOTION

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Counter Measure•Moved lockout record book to point of lockout

Cause•Walking to opposite ends of machine to record lockouts

EffectAdded time and extra steps to the process

BEFORE AFTER

BEFORE AFTER

beforeafter

Cause•Walking in and out of moulder to use computer

Counter Measure•Put wireless mouse inside moulder to control computer from inside machine

EffectAdded time and extra steps to the process

Counter Measures – MANUAL CALCULATIONS

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BEFORE AFTER

Counter MeasureCreated formula on drawing on computer that automatically calculates head set up location when grinding room enters new diameter of head after being sharpened

CauseTicket inserted into each head by the grinding room so operator can manually calculate where the heads need to be set based on the diameter of the head

EffectTime consuming and possible miscalculation

Counter Measures – WAITING

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Counter MeasureAdded more tools and supplies in optimal areas

CauseNot enough tooling or supplies

EffectWaiting for other operator to finish using tools needed

Results

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• Operator 1 steps reduced from 2,002 steps to 1,055 steps (47%)• Operator 2 steps reduced from 1,000 steps to 650 steps (35%)

-Set ups per day went up from average 8 per day to average 10 per day (25%)-Reduced set up time from 58 min to 38 min (35%)

Follow-up Plan

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Outstanding Actions:

-hydro hubs for universal saw blades set up

-computer monitors on infeed end of moulder for drawing visual-siko guages installed on universal heads-implementing improvements from this kaizen on our other 2 moulders

Monitor/Sustain Gains:

-track number of set ups and length of time set ups take-40% below base line-60% above base line