CH-148 Position 3 Kaizen

02/03/2010 - 02/05/2010

The ACE Office, Sikorsky Aircraft 2

CH-148 Position 3 Kaizen

Problem Statement

CH-148 Position 3 does not currently meet the 6S Silver standard, a score of 3.6 or greater. The area is lacking visual aids, proper staging areas for incoming parts, and visual communication of aircraft build status.

The ACE Office, Sikorsky Aircraft 3

CH-148 Position 3 Kaizen

Team

– Sponsor: Rob Von Stralendorff

– Leader: George Bowman

– Facilitator: Caitlin Murphy

Team Members:

George Bowman – CH-148 Supervisor (1st Shift)Kelly NubeloDave LittleJerome AnglinAndrew Miller – CH-148 Supervisor (2nd Shift)J.P. TabbertAaron Savela Debra Carrier – ACE Pilot

David Teixeira – DFC FacilitiesPWR – Graphics DepartmentMike Burns - EH&S ManagerBob Dolberg – T-ToolsKevin Pengue – Tool CribRoger Prickett – Material Logistics

Resources:

The ACE Office, Sikorsky Aircraft 4

CH-148 Position 3 Kaizen

Kaizen Objectives

• To create a flexible work space that can transition smoothly from development battleship build to production position build

• To develop a process so only components currently in work will be present on the manufacturing floor, resulting in a visual pull system

• To create additional workspace so that subassemblies (fairings, racks, tail rotor pylon, etc) can be built and introduced easily into production flow

• To introduce visual aids to promote standardization throughout shop and in staging areas

• To discover and address any EH&S issues on the CH-148 product line• To work toward a 6S score at or above the Silver level standard by

creating an ordered and efficient work cell including the shop floor and supervisor areas

The ACE Office, Sikorsky Aircraft 6

CH-148 Position 3 Kaizen

Current State

The ACE Office, Sikorsky Aircraft 7

CH-148 Position 3 Kaizen

Rubbish bin

Day can

Electrical box

Mechanical box

Sheet metal box

Work table

Panel board4 Step stairs

Counter top

Parts Rack

Solumina terminal

Desk Cabinet2 Step Stairs

Initial Layout

The ACE Office, Sikorsky Aircraft 8

CH-148 Position 3 Kaizen

Team Schedule

Time Wednesday Feb 3rd Thursday Feb 4th Friday February 5th

11:30 AMKick-Off:Review objectives with entire group.

Review feedback from 2nd shiftBrief update from all team leaders to group

Review feedback from 2nd shiftBrief update from all team leaders to group

1:00 PM 15 min break 15 min break 15 min break

2:00-2:30 PMCommunicate objectives and present status to 2nd shift

Communicate status to 2nd shift

Communicate status to 2nd shift

4:00 PM 15 min break 15 min break 15 min break

5:15 PM Prepare for daily briefing Prepare for daily briefing Prepare for daily briefing

5:30 PMManagement brief presented by team leaders

Management brief presented by team leaders

Management brief presented by team leaders

The ACE Office, Sikorsky Aircraft 9

CH-148 Position 3 Kaizen

Needs Assessment

Work surfaces for subassemblies

3 ring binders and tabs

File folders

SuppliesFloor tape, label maker, laminating supplies, garbage bags, tie wraps, 1” double-sided tape, Velcro

6S Training documents

Chart Pad/Easel/Markers

The ACE Office, Sikorsky Aircraft 10

CH-148 Position 3 Kaizen

KAIZEN NEWSPAPERIssue/Opportunity Responsible Due % completion Comments

Identify and remove unnecessary equipment Team   100%  

Identify and mark proper staging areas Team   100%  

Double-sided signs for Jack Storage and Recycling Center Caitlin   90% George to request install

Component Staging (POUS) Team   100%  

Eyewash (bottles) for A/C stand George/Debbie   100%  

Remove T-tooling not in use Tool Crib   100%  

Safety glass cleaner for stand Debbie   100%  

Ear Plug Dispenser Debbie   100%  

Standard Work Signs for Solumina & labor ACE/Supervisors   75% Julian Cox (Solumina)/ Eric Mathias

Standard Work Signs for daily cleaning and housekeeping George/Red   75% George/Red to review with Black Hawk Supervisors

Move tool boxes and table to top deck Red   100%  

Communication board Rob/Red/Caitlin   100%  

Replace safety tape on stand Team   100%  

Return A/C 801 and 802 hardware to PC Team   100%  

Relocate A/C 803 and 804 hardware to Positions 1 and 2 Team   100%  

Collection system for certs. George/Anthony/Kevin L.   90%  

Hang warning signs: "Aircraft on Jacks" and "Radar in Use" Debbie   100%  

chairs for this position Kevin/Team   90% Need Blue supervisor chairs

Need string lights inside A/C Kevin/ACE   100%  

Order shelves for storage of stools and box fans Red/Debbie   100%  

Relocate Metcals Team   100%  

Engineering table for parts/jobs requiring attention from Engineering Kevin/ACE/Brandon/Red   75% moved to communication board

American flag (and smaller Canadian) for all work stations Debbie   100% approved

    Total: 100%  

The ACE Office, Sikorsky Aircraft 11

CH-148 Position 3 Kaizen

Staging

Staging (tooling, hardware, etc)

Electrical Area

Engineering Table

Fairing AreaCommunication

Board

Parts Rack

CH-148 Position 3 Jack Storage

New Layout

The ACE Office, Sikorsky Aircraft 12

CH-148 Position 3 Kaizen

Staging

Staging (tooling, hardware, etc)

Mech.

Elec.

Electrical Area

Engineering Table

Fairing AreaCommunication

Board

Parts Rack

CH-148 Position 3 Jack Storage

Mech.

Stairs

Stairs

Elec.

60 trips 3min= 3hrs60 trips X 76ft=4,636ft

60 trips 10 sec.=12min60 trips X 12ft=720ft

Mechanical Savings: Time 2:48 hrs/Walking 3,916 ft.Electrical Savings: Time 3:47/walking 3,576 ft.

Mechanical top Deck 27 AOS’s

Electrical top Deck 2 Major AOS’s80 trips 3min= 4hrs

80 trips X 56ft=4,536ft80 trips 10 sec.= 13min80 trips X 12ft=960ft

New Layout Savings: tool box relocation

The ACE Office, Sikorsky Aircraft 13

CH-148 Position 3 Kaizen

CH148 Set-up Reduction EventFeb.19, 2010

Top Deck Electrical and Mechanical AOS’s installs

Mechanical 27 AOS’s InstallsBefore60 trips 3min= 3hrs60 trips X 76ft=4,636ftAfter60 trips 10 sec.=12min60 trips X 12ft=720ftMechanical Savings: Time 2:48 hrs/Walking 3,916 ft.

Electrical Installs 2 Major AOS’s and multiple minorsBefore80 trips 3min= 4hrs80 trips X 56ft=4,536ftAfter80 trips 10 sec.= 13min80 trips X 12ft=960ftElectrical Savings: Time 3:47/walking 3,576 ft.

New Layout Savings: tool box relocation

The ACE Office, Sikorsky Aircraft 14

CH-148 Position 3 Kaizen

New Layout Savings: Metcal Relocation

The ACE Office, Sikorsky Aircraft 15

CH-148 Position 3 Kaizen

Metcal's CH-148

BeforeSince moving the curtain on the Ch-148 they now have to walk around to get their Metcal's

Feet Minutes1. Operator goes to the Metcal area 250 152. Operator returns to work area 250 5

Total 500 203. Process is repeteted Avg. 20 times x20 x20

Total 10,000 400

After Metcal bins were moved,to the Ch-148 side and mountedon wall in central location

Feet Minutes1. Operator goes to the Metcal area 20 52. Operator returns to work area 20 5

Total 40 103. Process is repeteted Avg. 20 times x20 x20

Total 800 200

Total Savings = 9,200 200

New Layout Savings: Metcal Relocation

The ACE Office, Sikorsky Aircraft 16

CH-148 Position 3 Kaizen

PERFORMANCE

SCHEDULE

TREND HOURS STATUS BOARD

QCPC

TURNBACK TRENDS TURNBACK TRENDS

6S ASSESSMENT FORM

6S AUDIT SCHEDULE

6S AUDIT TREND

6S ACTION LIST

6S METRICS

AREA OWNERS

1ST SHIFT

PERSONNEL

2ND SHIFT

Description for all stations, all shif ts

SEATING

Engineering Issues (dry erase)

Upcoming Events/Training

(dry erase)

PART SHORTAGES TOOLING/RAWMA NEEDS

MAJOR MILESTONES

Communication Board Layout(front)

The ACE Office, Sikorsky Aircraft 17

CH-148 Position 3 Kaizen

Communication Board Layout(back)

24 X 36

Dry Erase

(part shortages noticed during shift

and significant notes)

12 X 18

MRB

11 X 17

2nd Shift Plan

11 X 17

1st Shift Plan

11 X 17

2nd Crew Load

11 X 17

1st Crew Load

8.5 X 11

Removed Parts

BondingBook

Serial NumberBookElec. CrabsMech. Crabs

11 X 17

Part Shortages

COPQ

COPQ HISTORY

DR HISTORY

CRAB COUNT HISTORY

MRB HISTORY

TIP OF THE DAY

The ACE Office, Sikorsky Aircraft 18

CH-148 Position 3 Kaizen

Out Brief Presentation