final review elaine mau procter and gamble
TRANSCRIPT
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FINAL REVIEW
Elaine Mau // Professional Supply Chain Intern
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Overview
� Projects
� Progress at Midpoint
� Since Midterm
� Follow-up
� Success Criteria and Milestones
� Questions
� Acknowledgement
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Priority 1
FI on Line 12 Un-scrambler
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Progress at Midpoint
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Step 3: Analyze Causes
� Bowl Exit Chute� Where: Top and bend of chute outside the bowl
� Phenomenon: Bottles getting jammed between rail or sticking to rail
� Why 1: Worn electrical brushes on preorienter motor cause erratic stops and goes, resulting in uneven flow of bottles and therefore produced jams
� Why 2: The coating on railings caused too much friction and constricted the area in which the bottle can pass through.
� Why 3: Dimensions of the chute did not direct bottles as designed.
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Step 4 & 5: Plan and implement improvement
� TBM (PM 1656) for electrical brushes
� Use spare chute
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Step 6: Check Results
Results for Brushes Replaced
0
2
4
6
8
10
12
14
Bowl Exit
Chut e
Turn
Table
Flipped
Bot t les
Paddle
Wheel
Bowl
Phot oeye
Slot
Ot her Overf ill Bad
Bot t les
No
Bot t les
Baseline Brushes replaced
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Step 6: Check Results
Results for Replacing Existing Chute with Line 10 Chute
0
2
4
6
8
10
12
14
16
18
Bowl Exit
Chute
Turn
Table
Flipped
Bottles
Paddle
Wheel
Bowl
Photoeye
Slot
Other Overfill Bad
Bottles
No
Bottles
Av
era
ge
Nu
mb
er
of
Sto
ps
Pe
r S
hif
t
Baseline Replaced Chute
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Step 3: Analyze Causes
� Fallen Bottles� Where: On the conveyor as bottles exits the unscrambler
� Phenomenon: Bottles get stuck in the space when it falls.
� Why: Bottles have room to get stuck.
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Step 4 & 5: Plan and implement improvement
� Lowered rails and centerlined
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Step 3: Analyze Causes
� Turn Table� Where: As bottles flip up onto the conveyor
� Phenomenon: Bottles jams between rails and conveyor
� Why: Buckets and rails are not in correct centerlines (unmarked)
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Step 4 & 5: Plan and implement improvement
� Rails moved and centerlined
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Step 3: Analyze Causes
� Paddlewheel� Where: Paddle wheel
� Phenomenon: Bottles jams between rails and paddle wheel
� Why: Gap allows bottles to get stuck
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Step 4 & 5: Plan and implement improvement
� Paddlewheel moved closer and centerlined
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Step 6: Check Results
Final Results for FI Unscrambler Project
0
2
4
6
8
10
12
14
Bowl Exit
Chute
Turn
Table
Flipped
Bottles
Paddle
Wheel
Bowl
Photoeye
Slo t
Other Overfill Bad
Bottles
No
Bottles
Av
era
ge
Nu
mb
er
of
Sto
ps
Pe
r S
hif
t
Baseline Present
85% reduction
100%91%
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Step 7: Consolidate Gains
� Replaced rail with spare chute
� Pin the paddlewheel at new position
� Pin conveyor rail to prevent fallen bottles
� Centerline turntable rails
� Unscrambler speed centerlined and added in documentation
� Centerline audit added to CIL
� Reapplication unscrambler improvements Ln 10, Ln 5
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Success Criteria and Milestones
� Success Criteria
� Reduce minor stops due unscrambler from 8.33% PR (40 minutes) to 3.23% PR (15 minutes) per shift
� Milestones
� Achieved 3.03% PR (14.5 minutes) minor loss
� Significantly reduced bowl exit chute jams
� Eliminated fallen bottle and paddlewheel problems
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Priority 1
Line 12 Speed Optimization Analysis
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Progress at Midpoint
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Results
Minor Stops
Loss
PR
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Optimal Speed and Observations
� Constraint Factors
� Unscrambler
� Labeller Slugs
� Ratio of speed between each unit op.
Un-scramblerDye-
Filler/CapperLabeller Cartoner
210 207 210 216
3-4 bottles
faster
3 bottles
slower
Belt Speed:
1.00 ft/sec
Constraint
Machine
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Additional Work
� Uneven bottle piles in chute� Where: Between long and short conveyor belt
� Phenomenon: Synchronization of long and short belt and eyes
� Why: Bottle material causes sticking between bottles as well as belt set-up create alternating large and small piles of bottles
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Plan and implement improvement
� Electrical- Maxi-Beam Sensor Head
� Mechanical- Add-on
� Speed adjustment to make up any losses
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Additional Work
� Falling bottles� Where: Between unscrambler and dye-filler/capper
� Phenomenon: Bottles fall on conveyor belt
� Why: Balance of forces from hitting against each other and from belt friction
F
F
F
FFFriction
N
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Plan and implement improvement
� Cleaned to baseline condition
� Work order for missing zerk fitting and hose
� Optimal Speed: 1.00 ft/sec, posted
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Actions to sustain the gain
� Centerlines posted on each equipment, belt, unscrambler
� OPL on speed analysis results
� Work order for zerk fitting tubing
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Follow-up
� Unscrambler
� Ability to run faster
� Additional mechanical adjustment and replacements
� Labeller Slug Issue
� Thermal Imaging Unit
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Success Criteria and Milestones
� Success Criteria
� Familiarized with line personnel
� Validated lines speeds posted on each unit op.
� Minor stops PR reduction by 2%
� Milestones
� Familiarized with line personnel
� Validated line speed posted on each unit op.
� Minor stops PR reduction by 7%
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Priority 2
Line 10 Rapid Changeover
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Progress at Midpoint
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Step 1: Understand the Situation
Purging Bottle
Chute
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Step 2 & 3: Identify improvement Ideas and plan the improvements
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Step 2 & 3: Identify improvement Ideas and plan the improvements
� Separate Internal from External
� Streamline the internal
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Step 2 & 3: Identify improvement Ideas and plan the improvements
� Streamline Internal
� Perform Parallel Operations
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Task Sheets
� Training material to implement changes
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Step 4: Implement Improvements
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Step 4: Implement Improvements
� Major Loss: Bottle Dumping (up to 1½ hrs!)
�Meetings
�OPLs
� Visual Control
PLANNER LTBOTTLE DUMPER COORDINATOR
Product Labels Shippers
Bottles and
Caps
Changes in scheduleScrap material
Over/under usage
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OPLs for Bottle Dumping
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Visual Controls
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Step 5: Check Results
Saves 31.3
Minutes!
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Step 6: Consolidate Gains
� Drip pan installed
� Chutes have visual controls for bottles and caps
� OPLs for bottle dumping procedure for normal production and brand to brand change over
� Task Sheets for B/C -> Jazzing
� Reapplication- any line that requires many changeovers
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Follow-up
� Continued work with bottle dumpers and line technician, Lena Dushku
� This week:
� Final Training Session (sign), planned for Tuesday, August 12th, 2008 both shifts
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Success Criteria and Milestones
� Success Criteria
� Reduce c/o time from 100 minutes to 80 minutes
� Milestones
� Reduce c/o time from 100 minutes to 60-70 minutes
� Eliminated bottle excess during changeover
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Priority 3
Y-Y Analysis on Line 15 Kalish Filler
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Erratic fill weight for gallon bottles
� Where: Filler nozzle
� Phenomenon: Pumps do not fill bottles with consistent weights
� Why 1: Because of hot water washouts, aculyn build up causes different torques on each motor
� Why 2: Pumps gears are worn out
� Why 3: Leaking nozzles had wrong O-rings
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Actions Implemented to Sustain the Gain
� Adjusted SOP to use cold DI water vs hot DI water
� Nick Dushku and Joseph Iorfino will continue validation work
� Reapply approach from line 33 developer filler to manage idle time
� This week:
� Change to new pumps
� Continue with cold water washout
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Priority 3
Y-Y Analysis on Line 1 Conditioner Filler
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Heating Cone Contamination on Line 1 Conditioner Filler
� Where: Heating cone
� Phenomenon: Leaking nozzles leads to contamination of heater cones
� Why 1: Leaking nozzles due to worn nozzle stems.
� Why 2: Leaking nozzles due to unsynchronized nozzle closing.
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Results
� Day 1 Baseline � Week 1 Present� Day 1 Present
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Actions Implemented to Sustain the Gain
� TBM from 1 year to 8 months
� Centerline
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Thank you!
Travis Gombos, Karnik Patel, Joseph Deleo, Kevin Shaw, RanjithMathew
Miguel Paz, Charlie Popp, Peter Bybel, David Velez, Rocco Catalano, Jerry Talis, Geraldine Miller, Douglas, Age I., Eduardo, Tony, Marizol, Paul, Emmillianne, Lena Dushku, Mary Thompson
Bob Fitts, Eddie Lopez, Bob Flitner, Ernie, Tony, Lee Copolla, Luis, Alexis, Nestor Mendez
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Any Questions?