1st Quarter Paint Line Process Improvement Project

GOAL: Optimize Parts Hanging Capacity on the Paint Line

Current Annual Costs to Paint 24 Parts Identified = $327,984

1

Process Improvement Methodology

• Identify highest volume painted parts• Modify existing tooling or design new tooling

to hang more parts per foot• Design and test samples of new tooling• Build tooling quantities for production• Create Paint Line Work Instructions• Calculate projected throughput increases and

cost savings2

Identify Highest Volume Painted Parts

3

Rank P/N Description Where Used EAU

1 201-0449 HOOK BRKT ST635,640,650,660 RAW ST6% 264,172

2 095-0721 ADPR PLATE, RAW PP740 184,179

3 201-0440 ADPT BRKT, ST650/ST660, RAW ST6% 160,494

4 201-0437 ADPT BRKT, ST640, RAW ST6% 157,974

5 201-0508 SMART FLAT SLIM ADPT BKT 18", RAW SF6% 66,557

6 640-0017 PA/PP 74X SHORT ARM PA740 64,746

7 640-0001 WALL PLATE, PP740 (CSTD,FNSHD,HT) PA730 56,738

8 095-0660-2 PLATE, WALL, SA730,SA740 SA730P 52,533

9 201-0509 SMART FLAT MINI ADPT BKT 13.75",RAW SF6% 51,362

10 201-0507 SMART FLAT DEEP ADPT BKT 18", RAW SF6% 47,378

11 640-0005 WALL PLATE (SYM # 840A-0001), RAW PA740 38,784

12 201-0434 ADPT BRKT, ST635, RAW ST6% 30,832

13 630-0019 PA730 SHORT ARM PA730 25,332

14 095-0605 PLATE, PLP, SA745/50/60/70,RAW SA745 16,244

15 201-0156 SCREEN MOUNT BRACKET SR560M 10,460

16 201-0157 HOOK ON SCREEN PLATE SR560M 10,340

17 095-0942-2 VERT. BRKT, SCALABLE,400x400,RAW SA746PU 10,099

18 630-0020 PP730 SHORT ARM PP730 8,121

19 201-0302 FAB, VERT. BRKT, PFT640 PF6% 6,125

20 046-0064 PLATE, SPACER SAU745PU 5,016

21 200-0939 ST670 LRG FLAT DEEP ADPTR BRKT, RAW SF6% 4,840

22 201-0446 ADPT BRKT, ST680, RAW ST6% 3,750

23 201-0308 FAB, VERT. BRKT, PFT660 PF6% 2,436

24 200-0938 ST680 LRG FLAT DEEP ADPTR BRKT, RAW SF6% 1,654

Modify Existing ToolingP/N 640-0001 Wall Plate (PA730)

• Before Hanging Pattern– 5 pieces per foot– 4,200 pieces per hour

• After Hanging Pattern– 6 pieces per foot– 5,040 pieces per hour

4

HT-0812

Design & Test New ToolingP/N 640-0005 Wall Plate (PA740)

• Before Hanging Pattern– 3.75 pieces per foot– 3,150 pieces per hour

• After Hanging Pattern– 5 pieces per foot– 4,200 pieces per hour

5

HT-1010

Design & Test New ToolingP/N 095-0721 Adapter Plate (PA740)

• Before Hanging Pattern– 2.25 pieces per foot– 1,890 pieces per hour

• After Hanging Pattern– 4 pieces per foot– 3,360 pieces per hour

6

HT-1308

Design & Test New ToolingP/N 640-0017 Short Arm (PA740)

• Before Hanging Pattern– 5 pieces per foot– 4,200 pieces per hour

• After Hanging Pattern– 5.5 pieces per foot– 4,620 pieces per hour

7

HT-3522

Design & Test New ToolingP/N 201-0440 Adapter Bracket (ST650)

• Before Hanging Pattern– 3 pieces per foot– 2,520 pieces per hour

• After Hanging Pattern– 4 pieces per foot– 3,360 pieces per hour

8

XB-4008

Create Paint Line Work Instructions to Execute

New Tooling and Hanging Patterns

9

10

Throughput ImprovementsBefore Before After After %

Parts per Parts per Parts per Parts per Throughput

Rank P/N Description Foot Hour Foot Hour Increase

1 201-0449 HOOK BRKT ST635,640,650,660 RAW 3.75 3,150 5.00 4,200 33%

2 095-0721 ADPR PLATE, RAW 2.25 1,890 4.00 3,360 78%

3 201-0440 ADPT BRKT, ST650/ST660, RAW 3.00 2,520 4.00 3,360 33%

4 201-0437 ADPT BRKT, ST640, RAW 3.00 2,520 4.00 3,360 33%

5 201-0508 SMART FLAT SLIM ADPT BKT 18", RAW 3.00 2,520 4.00 3,360 33%

6 640-0017 PA/PP 74X SHORT ARM 5.00 4,200 5.50 4,620 10%

7 640-0001 WALL PLATE, PP740 (CSTD,FNSHD,HT) 5.00 4,200 6.00 5,040 20%

8 095-0660-2 PLATE, WALL, SA730,SA740 3.75 3,150 5.00 4,200 33%

9 201-0509 SMART FLAT MINI ADPT BKT 13.75",RAW 3.00 2,520 4.00 3,360 33%

10 201-0507 SMART FLAT DEEP ADPT BKT 18", RAW 3.00 2,520 4.00 3,360 33%

11 640-0005 WALL PLATE (SYM # 840A-0001), RAW 3.75 3,150 5.00 4,200 33%

12 201-0434 ADPT BRKT, ST635, RAW 3.00 2,520 4.00 3,360 33%

13 630-0019 PA730 SHORT ARM 5.00 4,200 5.50 4,620 10%

14 095-0605 PLATE, PLP, SA745/50/60/70,RAW 3.00 2,520 5.00 4,200 67%

15 201-0156 SCREEN MOUNT BRACKET 2.25 1,890 5.00 4,200 122%

16 201-0157 HOOK ON SCREEN PLATE 2.25 1,890 5.00 4,200 122%

17 095-0942-2 VERT. BRKT, SCALABLE,400x400,RAW 3.00 2,520 4.00 3,360 33%

18 630-0020 PP730 SHORT ARM 5.00 4,200 5.50 4,620 10%

19 201-0302 FAB, VERT. BRKT, PFT640 3.00 2,520 4.00 3,360 33%

20 046-0064 PLATE, SPACER 3.00 2,520 4.00 3,360 33%

21 200-0939 ST670 LRG FLAT DEEP ADPTR BRKT, RAW 3.00 2,520 4.00 3,360 33%

22 201-0446 ADPT BRKT, ST680, RAW 3.00 2,520 4.00 3,360 33%

23 201-0308 FAB, VERT. BRKT, PFT660 3.00 2,520 4.00 3,360 33%

24 200-0938 ST680 LRG FLAT DEEP ADPTR BRKT, RAW 3.00 2,520 4.00 3,360 33%

Tested

78%

122%

67%

Cost Savings

11

Before After Per  

Cost per Cost per Piece Annual

Rank P/N Description EAU Piece Piece Savings Savings

1 201-0449 HOOK BRKT ST635,640,650,660 RAW 264,172 $ 0.22 $ 0.16 $ 0.05 $ 14,257.53

2 095-0721 ADPR PLATE, RAW 184,179 $ 0.36 $ 0.20 $ 0.16 $ 28,992.42

3 201-0440 ADPT BRKT, ST650/ST660, RAW 160,494 $ 0.27 $ 0.20 $ 0.07 $ 10,827.45

4 201-0437 ADPT BRKT, ST640, RAW 157,974 $ 0.27 $ 0.20 $ 0.07 $ 10,657.45

5 201-0508 SMART FLAT SLIM ADPT BKT 18", RAW 66,557 $ 0.27 $ 0.20 $ 0.07 $ 4,490.15

6 640-0017 PA/PP 74X SHORT ARM 64,746 $ 0.16 $ 0.15 $ 0.01 $ 953.01

7 640-0001 WALL PLATE, PP740 (CSTD,FNSHD,HT) 56,738 $ 0.16 $ 0.13 $ 0.03 $ 1,531.09

8 095-0660-2 PLATE, WALL, SA730,SA740 52,533 $ 0.22 $ 0.16 $ 0.05 $ 2,835.24

9 201-0509 SMART FLAT MINI ADPT BKT 13.75",RAW 51,362 $ 0.27 $ 0.20 $ 0.07 $ 3,465.05

10 201-0507 SMART FLAT DEEP ADPT BKT 18", RAW 47,378 $ 0.27 $ 0.20 $ 0.07 $ 3,196.28

11 640-0005 WALL PLATE (SYM # 840A-0001), RAW 38,784 $ 0.22 $ 0.16 $ 0.05 $ 2,093.20

12 201-0434 ADPT BRKT, ST635, RAW 30,832 $ 0.27 $ 0.20 $ 0.07 $ 2,080.03

13 630-0019 PA730 SHORT ARM 25,332 $ 0.16 $ 0.15 $ 0.01 $ 372.87

14 095-0605 PLATE, PLP, SA745/50/60/70,RAW 16,244 $ 0.27 $ 0.16 $ 0.11 $ 1,753.40

15 201-0156 SCREEN MOUNT BRACKET 10,460 $ 0.36 $ 0.16 $ 0.20 $ 2,069.95

16 201-0157 HOOK ON SCREEN PLATE 10,340 $ 0.36 $ 0.16 $ 0.20 $ 2,046.21

17 095-0942-2 VERT. BRKT, SCALABLE,400x400,RAW 10,099 $ 0.27 $ 0.20 $ 0.07 $ 681.31

18 630-0020 PP730 SHORT ARM 8,121 $ 0.16 $ 0.15 $ 0.01 $ 119.54

19 201-0302 FAB, VERT. BRKT, PFT640 6,125 $ 0.27 $ 0.20 $ 0.07 $ 413.21

20 046-0064 PLATE, SPACER 5,016 $ 0.27 $ 0.20 $ 0.07 $ 338.40

21 200-0939 ST670 LRG FLAT DEEP ADPTR BRKT, RAW 4,840 $ 0.27 $ 0.20 $ 0.07 $ 326.52

22 201-0446 ADPT BRKT, ST680, RAW 3,750 $ 0.27 $ 0.20 $ 0.07 $ 252.99

23 201-0308 FAB, VERT. BRKT, PFT660 2,436 $ 0.27 $ 0.20 $ 0.07 $ 164.34

24 200-0938 ST680 LRG FLAT DEEP ADPTR BRKT, RAW 1,654 $ 0.27 $ 0.20 $ 0.07 $ 111.58

Tested

$ 94,029.22

Cost Savings

12

Top 5 Parts Top 10 Parts Top 15 Parts Top 20 Parts Top 24 Parts $-

$10,000.00

$20,000.00

$30,000.00

$40,000.00

$50,000.00

$60,000.00

$70,000.00

$80,000.00

$90,000.00

$100,000.00

$69,225.00

$82,894.79

$91,248.46 $93,380.77 $94,355.74

Cost Savings

Cost Savings

Conclusions

13

GOAL: Optimize Parts Hanging Capacity on the Paint Line

Annual Costs to Paint 24 Parts Identified Current = $327,984 Projected = $233,956Projected Annual Savings = $94,028