KAIZEN – PRESSLINE REJECT REDUCTION

2

PRESSLINE KAIZEN

Project Scope•Reduce Pressline Damage and Backrinding Rejected Pads by 50%

3

Pressline TeamChuck Scarborough

Catalino OsorioShawn Baldwin

Ricky Lucas

Facilitators: Duke Bedsole

Tony Perez

4

Pressline IMPACT Team

5

Problems Identified:– Pressline damage is SEP’s #1 reject.– Pressline damage and Backrinding make up 27% of

SEP’s rejects.– There are no formal procedures or work

instructions for the Pressline.– Press Operators do not receive formal training or

evaluations.– Press Operators are not aware of the true cost of

rejects or the impact rejects have on the company.– Press Operators feel that they don’t have a voice in

troubleshooting and problem-solving problem jobs and area concerns.

6

7

Pressline Reject ReductionKaizen Process

• Kaizen / Continuous Improvement training• Weekly Roundtable Discussions• Brainstorm Problem Resolutions• Idea Generation• Review Weekly Rejects and Task List

8

Weekly Roundtable

9

Solutions•Build a repair table•Write procedures and work instructions•Implement formal training on the Pressline•Engage in open dialogue with the experts that do the job every day•Try new mold releases•New “no-touch” tooling design•Weekly reject #’s communication•Initial and periodic evaluations for Press Operators

10

11

12

“No Touch” Tooling

1

2

3

13

14

15

Outcome / Deliverables•12 Tasks identified, 6 complete•Pressline Procedures & Work Instructions•Press Operator Evaluation•Repair table complete by Sept 2015•SPL’s

–Mold Release Application–Demolding

•Management Accountability•Team Building

16

Future State•Continue to hold regular reviews with team•Evaluate true savings realized from event•Foster an environment of continuous improvement•Apply same Kaizen / Roundtable meeting process in Steel Prep and Rubber Prep along with 6S activities

17

Estimated Cost Savings: Kaizen – Pressline Reject Reduction

IMPACTTarget

Improved Trend Savings NotesMetric

Waste Cost: $360k projected 2015 waste cost; $360k x 27% = $97.2k x 50% (projected Pressline Damage & Backrinding reject reduction) = $48.6k

Waste Cost $48,600 90% reduction of 2 major reject categories that made up 27% of SEP’s rejects.

Fewer change outs on Pressline due to not remaking rejects. Time $12,500

27% of rejects reduced by 90% = 20% fewer setups = 2 setups/day @ 1 hr/setup

x $25/hr x 250 days/yr = $12,500/yr

Reduced shipping costs due to improved on time delivery. Shipping Cost $5,000 Not shipping pads overnight or next day

due to rejects and frequent late jobs.

Fewer dumpster loads.

Cost $2,400

Reject pad dumpster pickups reduced from every 6 weeks to every 8 weeks @ $800/pickup = 9x/yr to 6x/yr. 3 x $800 =

$2,400

Total Estimated Savings: $68,500

18