ERJ DIVE

Company Private

ACCESSORIES SHOP

2

DEFINE

,Bill Borah

3

DEFINE CONT’D

Apr May0

5

10

15

20

25

ERJ Average Labor Hrs (Current)

Months

Labo

r H

rs

EVENT PRE-WORK ACTIVITIES                       

Part Family A                   Takt Time: 129

Part Number Description

Monthly Demand Pre Test Disassy Cleaning Inspect

Shimming Assy Test F. Prep

Total Work Content

  ERJ 75.0 45.0 60 60 150 250 160 40 30 720  Slat "CRJ" 30.0 45.0 60 60 150 240 160 40 30 710

Variation % 0 0 0 0 4 0 0 0 1.39

  Avg C/T 45.00 60.00 60.00 150.00 245.00 160.00 40.00 30.00 119.17

INVESTIGATE

5

INVESTIGATE CONT’DM

ater

ials

RO

AA

ctua

tion

Qua

lity

Receive Unit

Shop Incoming

Pre-Checks Dissy. Insp

Pull parts

Assy. Functional Test

Final Inspection

Final Prep

Ship Unit

Incoming PO

Review

Physical movement (Unit/paperwork)Electronic communication

Internal process

45 Min. 2 Hrs 2 Hrs 10 Hrs 1 Hr

0.5 Hr

6

INVESTIGATE CONT’D

Count of SO Average Sum of Hrs

12 Hrs Target Cum Avg 23.2

VERIFY CONT’D

Count of SO Average Sum of Hrs

12 Hrs Target Cum Avg 23.2

VERIFY CONT’D

Progression TimelineContact ASE for

recommendations of SB & CMM revision. Assign Action items and commit dates. Enhance shimming process through SB

change

Create Special Tooling for shim

stack up.

Complete time observation study of current state & cycle time reduction plan.

Conduct standard work Kaizen event.

Order cleaning tanks.

Obtain spring tester PO approval.

Obtain shimming software verification if standard shimming

process is not adopted.

5/23/11

5/28/11

5/31/11

6/5/11 6/10/11

6/15/11

6/20/11

6/30/11

Implement process gates on all benches

to monitor times.

11Hrs

by Aug

1

Benefits = 6Hr reduction

3Hr reduction

0.5Hr reduction

10 Min reduction2 Hr reduction

20 Min reduction

See standard work Kaizen

VERIFY CONT’D

ENSURE

No. Activity Owner Due Date

1 Enhance shimming process SB & CMM rec. Bowman/ Borah/ Dobbs 5/31/2011

2 Time observation study (current & future) Bowman/ Morales 5/31/2011

3 Incorporation of Process Gates Bowman/ Morales 6/1/2011

4 Standard Work Kaizen Event Bowman/ Morales 6/5/2011

5 SB ENG action items closed Borah/Porsche 6/12/2011

6 Spring Tester Quote and PO approval Bowman/ Mclaughlin 6/15/2011

7 Shimming software if standard shim process NV Anwar/ Bowman/Lyn. 6/30/2011

8 Order cleaning tanks Bowman/ Benn 7/1/2011

9 SB action item approval for standard shimming Borah/ Porsche 8/15/2011

10 Solvent PD680 added to CMM as alternative Borah/ Porsche 8/15/2011

% Complete

Team: ERJ Kaizen team Date: 08/05/11

11

ENSURE CONT’D

May-11 Jun-11 Jul-110

5

10

15

20

17.4

13.5311.66

ERJ Current Labor Hour Trend (Monthly)

Monthly Average Labor HrsGoal

Months

Aver

age

Labo

r Hou

rs

12 Hours

28 Units June

26 Units May

34 Units July

TOTAL TIME CURRENT STATE 12HRS

Mat

eria

lsR

OA

Act

uatio

nQ

ualit

y

Receive Unit

Shop Incoming

Pre-Checks Dissy. Insp

Pull parts

Assy. Functional Test

Final Inspection

Final Prep

Ship Unit

Incoming PO

Review

Physical movement (Unit/paperwork)Electronic communication

Internal process

45 Min. 1 Hrs 2 Hrs 7 Hrs 1 Hr

0.5 Hr

Reduced Times

ENSURE CONT’D