1. 1. IXL Group Productivity Improvement Project Presented by: Danish Khan Project sponsor: Bernard Brussow Project Leader: Glenn Meier Date: 23/03/2015
2. 2. Three Key Performance Issues Emptying of scrap bins Coil change Stillages Availability
3. 3. Scrap Bins Before After
4. 4. Cost Justification For Scrap Bins Previous average time 14 minutes Current average time 3 minutes Total time saved 11 minutes Scrape bin empties/day 3 Time saved per press / day 33 0.55 of an hour Press overhead rate $130 Dollars Total savings per press/day $71.50 Dollars Total number of presses 7 Total saving per day $500.50 Dollars Total savings per month $10,010.00 Dollars Scrap Bin
5. 5. Time Saved ! 14 3 11 33 0 5 10 15 20 25 30 35 Av. Before Av. After Time saved/press Time saved per press /day Time (Minutes) Time
6. 6. Cost 71.5 500.5 10,010 $0.00 $2,000.00 $4,000.00 $6,000.00 $8,000.00 $10,000.00 $12,000.00 cost per press cost per day cost per month Dollars Dollars
7. 7. Coil Change PressShop Foundry Logistics Backshed Coils TF2 1.5 Minutes Research and development Assembly Backyard Stillages Coils Relocation Map Stillages Coils
8. 8. Coil change Time (Minutes) Before After
9. 9. Cost Justification Previous average time 24 Minutes Current average time 12.9 Minutes Total time saved 11.1 Minutes No of time coil changes on a press 2 Time saved per press / day 22.2 0.37 of an hour Press overhead rate $130 dollars Total cost per press/day $48.10 dollars Total number of presses 7 Total cost per day $336.70 dollars Total cost per month $6,734.00 dollars Coil change
10. 10. Cost Justification 24 12.9 11.1 22.2 0 5 10 15 20 25 30 Av. Before Av. After Time saved/press Time saved per press /day Time (minutes) Minutes
11. 11. Cost Justification $48.00 $336.00 $6,734.00 $0.00 $1,000.00 $2,000.00 $3,000.00 $4,000.00 $5,000.00 $6,000.00 $7,000.00 $8,000.00 cost per press cost per day cost per month Dollars Dollars
12. 12. Stillages Relocation
13. 13. Before
14. 14. After
15. 15. Stillages Time (Minutes)Before After
16. 16. Cost Justification (Stillages) Previous average time 8 minutes Current average time 1.4 minutes Total time saved 6.6 minutes Stillage changes per day 4 Time saved per press / day 26.4 0.44 of an hour Press overhead rate $130 Dollars Total savings per press/day $57.20 Dollars Total number of presses 7 Total saving per day $400.40 Dollars Total savings per month $8,008.00 Dollars Stillages
17. 17. Cost Justification
18. 18. Cost Justification $57.20 $400.40 $8,008.00 $0.00 $1,000.00 $2,000.00 $3,000.00 $4,000.00 $5,000.00 $6,000.00 $7,000.00 $8,000.00 $9,000.00 cost per press cost per day cost per month Dollars Dollars
19. 19. Overtime Reduction Justification Scrap Bins Minutes Hours Average time saved per press/day 33 0.55 Ave. No of parts made per press 590 parts per press in 0.55 hours 324 Total Parts for 7 presses/day 2,268 Parts/week 11,340 Parts/month 45,360 Parts Parts Parts Parts
20. 20. Overtime Reduction Justification coil change Minutes Hours Average time saved per press/day 22.2 0.37 Ave. No of parts made per press 590 parts per press in 0.37 hours 218 Total Parts for 7 presses/day 1,526 Parts/week 7,630 Parts/month 30,520 Parts Parts Parts Parts
21. 21. Overtime Reduction Justification Stillages Minutes Hours Average time saved per press/day 26.4 0.44 Ave. No of parts made per press 590 parts per press in 0.44 hours 259 Total Parts for 7 presses/day 1,813 Parts/week 9,065 Parts/month 36,260 Parts Parts Parts Parts
22. 22. Overtime Reduction Justification Days
23. 23. TF2 Press Efficiency 0% 20% 40% 60% 80% 100% 120% 140% Efficiency Target Average
24. 24. Cevol Stillages Currently Hired 37 of the type D Stillages 80 of the SM1 Stillages Half of the SM1 Stillages (shown in the picture) can possibly be returned due to drop in Ford volumes.
25. 25. SM1 Stillages not in use
26. 26. Cevol Currently Hired Stillages 80 of the SS1 type Stillages. 19 of the SS3 type Stillages. Half of the SS1 type Stillages can be replaced by Backwells (PressFast) SS1 Stillages which require modification.
27. 27. Backwells (PressFast) SS1 Stillages Shown here are the Backwells Stillages that can be modified to replace the hired Stillages.
28. 28. Possible 50% savings on Hired Stillages Total current cost of hired Stillages is $1,075/month. A Savings of $500/month is possible by replacing the SS1 and returning the SM1 type Stillages.
29. 29. Project Benefits Total Savings of $20-25,000 a month. An end to the overtimes Continuous production process and Forklift availability issues. Data collection improved and can be used for further analysis and improvements. Employees Awareness. Less work load for press operators. Health and safety issues and standards.
30. 30. Thank you