Implementing and Leading a TPS like Facility - MNASQ.org · ASQ Presentation v1.ppt 1 Implementing and Leading a TPS like Facility by Michael Benner ASQ Presentation v1.ppt 2 Honeywell’s
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ASQ Presentation v1.ppt 1
Implementing and Leading a TPS like Facilityby Michael Benner
ASQ Presentation v1.ppt 2
Honeywell’s Businesses
Diverse Businesses, Technologies and Products
2006 Sales
$12B$12B
$5B$5B
$11B
$4BAerospaceSpecialty
Materials
Automationand Control Solutions
TransportationSystems Total = $31B
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ASQ Presentation v1.ppt 3
Golden Valley Facility Information
GVO is the largest ACS facility in North America
The Plant•70 Acre site (22 under roof)• 1.15M square feet (Factory is 700K sq ft)• Built in 1956; Office complex added in 1983• 500 Factory (Teamsters Local 1145)• 61 Salaried (Core GVO office & technical) employees
• Annual external Sales Revenue of $105M with over 3 million end items shipped•Applications include: Combustion controls, heating & ventilation products for home and commercial businesses, and pool & spa controls•Products include: thermostats, gas valves, ventilation actuators, electronic air cleaners, and boiler controls
• Externally demanded fabricated parts provide an additional $15mil of revenue
• Processes include: 14 assembly lines, die casting, plastic molding, stamping, metal finishing, machining, and glass forming/blowing.• Customers include (OEM, Trade & Retail): Trane, Lennox, Weil-McLain, Beckett, Yamatake, Johnstone Supply, R. E. Michel, Watsco, Inc., Ferguson, Gensco, Home Depot, Lowes
ASQ Presentation v1.ppt 4
Electronic Air Cleaners
Gas Valves
Factory Tour – October, 2006
Golden Valley Products
T87-Nonprogrammable thermostat
Mod IV – Foot mounted actuator
Oil Hydronics- residential burner safety devices
Optics-commercial boiler safety devices
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ASQ Presentation v1.ppt 5
Deming quotes“The key is to practice continual improvement and think
of manufacturing as a system, not as bits and pieces.”
“The worker is not the problem. Management is the problem.”
Compare Deming’s 14 points to the 14 principles describedin Jeff Liker’s The Toyota Way
ASQ Presentation v1.ppt 6
The U.S. Manufacturing Landscape A summary of results from the 2005 IW/MPI Census of Manufacturers.
By Tonya Vinas
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ASQ Presentation v1.ppt 7
The House of Toyota
Toyota Way PhilosophyPeople
Leveled Production (heijunka)/Single Piece FlowStandard Work and Kaizen
Just-in-Timeright part, right amount, right time
•Takt time•Continuous Flow
•Pull System•Quick changeover•Integrated logistics
Jidoka(In-station quality)
Make problems visible•Andon
•Automatic stops•Person-machine
separation•PDCA
•5 why’s/root cause •Mistake proofing
•SMED•TPM
Best Quality - Best Safety - Lowest Cost -Shortest Lead Time - High Morale
through shortening the production flow by eliminating waste
Continuous Improvement
People & TeamworkSelection - Common goals
Decision making - cross trained
Visual Factory
Continuous Improvement
ASQ Presentation v1.ppt 8
“Mechanism of Toyota Production System” by Shigeo Shingo; Productivity, Inc., 1981
Material Flow
Elimination of Waste
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ASQ Presentation v1.ppt 9
Strategy Owner: Kamar
HOS Tactical Implementation Cell by Cell Process Map
•VSM – Current•Waste Elimination•Single Piece Flow•Standard Work
Man:•Appropriate Staffing •Plan vs. Actuals have Counter-measures and Corrective Actions•Trained to Standard Work
Method:Built in Quality (BIQ) +ISO 9000 Adherence
No Daily Schedule EPED Schedule + AttainmentReliable Processes (OA) SMED
Owner: HOS Spec Owner: Operations
Machine: TPM
Materials:5S of materialPull Replenishment – internal and external
•Rapid Response •Problem Solving•Data Collection
Strategy Owner: Brian Strategy Owner: Nick Strategy Owner: Dan
Strategy Owner: Nick
•Hazard Assessment
Owner: Dale
Maturity Review
Maturity Review
SalesDemand mgt
Sourcing
CustomerValue
ASQ Presentation v1.ppt 10
House of Toyota
The Toyota Way Philosophy/ Organizational Design/ Maturity AssessmentPeople
Leveled Production / Single Piece FlowStandard Work and Kaizen
Material Flowright part, right amount, right time
•Takt time•Continuous Flow
•Pull System•Quick changeover
•Value Stream maps
Best Quality - Best Safety - Lowest Cost -Shortest Lead Time - High Morale
through shortening the production flow by eliminating waste
Continuous Improvement5 why’s/root cause
People & TeamworkSelection - Common goals
Decision making - cross trained
Visual Factory
Continuous Improvement
Process Design•Andon•PDCA•SMED•TPM
•Built in Quality•Hazard Screening
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ASQ Presentation v1.ppt 11
The Unspoken Story
Culture“Behavior”
“Lean”
Tacit
Explicit
Over 50 years later we are still
wrestling w/ Mass Production paradigm
Short term emphasis Tools and
ProjectsHow we work
The way we workMaking improvement
Communication
TWI
HOS SIF & Specs
Lean
SIF
6 Sigma
Leadership Std Work
OD
HOS SIF & Specs
ASQ Presentation v1.ppt 12
ShopFloorTeamOps
HSE Quality
Materials
Finance
HR
ShopFloorTeamOps
HSE
ProcessEngr
Materials
Finance
HR
ProcessEngr
Quality
Shop Floor TeamsIncreased Responsibility
Delegate and transition more responsibility to the shop floor.
Note the expanding gold ring.
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ASQ Presentation v1.ppt 13
ShopOps
ShopFloorTeam
HSE
ProcessEngr
Materials
Finance
HR
TPM
Quality
Tactical Interconnections
Design For
Flow
Hazard Assessment
Std Work
Set-upChangeover
MaterialFlow
ASQ Presentation v1.ppt 14
Waste #7 – Defective ProductsPrinciple – Built in Quality
Over 40 different Wires went into 19Different harnesses
Old work instructions
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ASQ Presentation v1.ppt 15
Wiring Table
Harness Assembly
Housing Wire 1 Common Wire 2 Norm. Open Wire 3 Norm. Closed
206806A 208546 Red 13" 873794AYB Vio 13" 873935AZF Orn 13" 873935ASY206806B 208546 Red 13" 873794AYB Blu 13" 873935AVP Yel 13" 873935AYJ206806C 208546 Red 32" 896794AYB Yel 32" 896935AYJ Blu 32" 896935AVP
206806D 208546 Red 56" 900794AYB Yel 56" 900935AYJ Blu 56" 900935AVP206806E 208546 Wht/Re
d 32" 896794AYM Wht/Yel 32" 896935AYQ Wht/Blu 32" 896935AYL
206806F 208546 Wht/Red
32" 896794AYM Wht/Blu 32" 896794AYL (no wire)
206806G 208546 Wht/Red
18" 878794AYM Wht/Yel 18" 878935AYQ Wht/Blu 18" 878935AYL
206806H 208546 Red 7" 861907AYBskinned1/2”
Blu 6.5" 860907AVP skinned 1/2”
(no wire)
206806J
208546 Red 7" 861907AYB skinned1/2”
(no wire) Yel 6.5" 860907AYJskinned1/2”
206806K OP 010
208546 Red 13.5" 919868AYB skinned 3/16”
Yel 13" 873868AYJ skinned 3/16”
Blu 13" 873868AVPskinned 3/16”
206806L 208550 Blk/Red 13" 873794AYP Blk/Vio 13" 873935CEB Blk/Orn 13" 873935CEC206806M 208550 Blk/Red 13" 873794AYP Blk/Blu 13" 873935AYR Blk/Yel 13" 873935AYN
206806N 208550 Blk/Red 32" 896794AYP Blk/Blu 32" 896935AYR Blk/Yel 32" 896935AYN206806P 208550 Blk/Red 56" 900794AYP Blk/Blu 56" 900935AYR Blk/Yel 56" 900935AYN206806Q 208550 Blk/Red 32" 896794AYP Blk/Yel 32" 896935AYN Blk/Blu 32" 896935AYR
206806R 208550 Blk/Red 13" 873794AYP No Splice
Blk/Yel 13" 873794AYN No splice
(no wire)
206806S 208550 Blk/Red 32" 896794AYP No splices
(no wire) Blk/Yel 32" 896794AYNNo Splices
206806T 208550 Blk/Red special
13" pin
873824AYP terminal
Blk/Yel special
12.5" pin
872824AYN terminal
(no wire)
206806U 208550 Blk/Red 18" 878794AYP Blk/Yel 18" 878935AYN Blk/Blu 18" 878935AYR206806V OP 010
208550 Blk/Red 11.5” 870868AYP skinned 3/16”
Blk/Yel 11” 869868AYN skinned 3/16”
Blk/Blu 11” 869868AYRskinned 3/16”
206806W 208546 Red 9" 865794AYB No Splices
Violet
9" 865794AZF No splices
Orange 9” 865794ASYNo splices
206806Y 208550 Blk/Red 9” 865794AYP No splice
Blk/Vio 9” 865794CEB no splice
Blk/Orn 9”
865974CECNo splice
206806Z 208550 Blk/Red 13” 873794AYP No splice
Blk/Yel 13” 873794AYN no splice
(no wire)
ASQ Presentation v1.ppt 16
New Standard Work InstructionPart Name Op or Station # Page
Harness 300 1 of 1
Ord
HARNESS TERMINAL FIRST TUBE
SECOND TUBE
THIRD TUBE TUBING
206806A WHITE 5 K @ £206806B WHITE 5 H # £206806C WHITE 10 Q ¢ £206806D WHITE 13 V Δ £206806E WHITE 11 S √ £206806F WHITE 11 P £206806G WHITE 8 N & £206806H WHITE 1 A £206806J WHITE 1 ÷ £206806K WHITE 15 G ! ;206806L BLACK 6 L % £206806M BLACK 6 J $ £206806N BLACK 12 T ↑ £206806P BLACK 14 W = £206806Q BLACK 12 R □ (206806R BLACK 6 F £206806S BLACK 12 + £206806T BLACK 7 E £206806U BLACK 9 M * £206806V BLACK 4 D ? /206806W WHITE 2 B Ø £206806Y BLACK 3 C ● £206806Z BLACK 6 F ¥
Group Leader QualitySteve Kolles Steve Volk
P9 When changing over to a new assembly or when shutting down, remove all wires from tubes and empty into storage totes and empty terminals and tubing back into storgage bins
P8When the tote the harnesses fall into after exiting the oven is full, unwrap the assemblies if they were wrapped and place in the appropriately marked tote
Place the bundle of wires in the tube labeled First Tube
Notes: For parts identification see routing
P4 Grab a bundle of tubing as specified in the Harness Table for Tubing
P5 Place the bundle of tubing in the Tubing Tray at the workstation
Place the bundle of terminals in the Terminal Tray at the workstationP7
P6 Grab a bundle of terminals as specified in the Harness Table
P3 Repeat steps P1 and P2 for the Second and Third Tubes
7 Slide tubing over wires and align on terminal
8 When assembling harnesses which are 32" or longer, wrap the harness
9 Place assembly in oven
P1
P2
Grab wire from the Second Tube and insert into the 2nd slot in the terminal5
6 Grab wire from the Third Tube and insert into the 3rd slot in the terminal
3 Grab terminal from Terminal Tray and insert into Harness Fixture
4 Grab wire from the First Tube and insert into the 1st slot in the terminal
Standard Work In Process: 0
Date Revised2Jerry Brooks
SecondsCycle Time: 34 Takt Time: 55.8
Standard Operating Sheet
3/1/2007Approved by
Process Steps
Engineer Rev
1 Grab tubing from Tubing Tray
Grab a bundle of wires as specified in the Harness Table for the First Tube
OS or Part Number
206806X
Name Initials
Alt. Process
2 Mark tubinng with last letter of harness being assembled. Leave tubing to allow ink to dry
HARNESS TABLE
Seconds
Process Description
Harness Assembly
Std. Op Code
J30A
QC Work Content Verify Notes Safety
Tug the wire after inserting into the terminal to ensure it
is securely fastened
2
7
8
Verify the tubing is not over the end of the
terminal
Verify the oven is at 300° +/- 5°
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ASQ Presentation v1.ppt 17
Work Station Visualization to Mistake Proof
Number Alpha Symbol
ASQ Presentation v1.ppt 18
NEW PARTS RACK
OLD TOTE IDENTIFICATION NEW TOTE IDENTIFICATION
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ASQ Presentation v1.ppt 19
Single Piece Flow Improvement
ASQ Presentation v1.ppt 20
Material Flow- Milk Run Cart
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ASQ Presentation v1.ppt 21
Visual Management
Hour x Hour chart
Progress visual at a section of line in MOD IV
ASQ Presentation v1.ppt 22
Daily Accountability
Steve (GL) getting the Hr x Hr chart ready for the dayProblem explanation at the Tier 2 daily meeting
Michael leading the daily Tier 4 meetingTier 3 meeting – discussion daily cell output
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ASQ Presentation v1.ppt 23
Plant Manager Standard Work Panel M T Panel 4
2-3 W T ~ Always take opportunity to teach / F S ~ Always monitor standardized work
~ Make progress to goal(s) visible~ Always monitor for the 3M's [Waste] in your Work Area:
7 Forms of Waste [DOTWIMP]Task performed inconsistenlyThings that prevent work fromflowing.Excessive physical stress &strain to perform task.
Review "Daily Routine Management Board" (CI) Boards
Hold Daily Production meeting
Verify 5S Condition and address variance
Audit HOS Improvement Team Meetings
Confirm PDCA cycles for "Top Five" Things found wrong
Monitor shift starts and shift ends as well as break times.
Conduct Factory walk with Manu. Leader to observe and identify waste and improve.
Weekly check Manu. Leader and Ops Leader Std. Work
Assure proper deployment of human resources throughtout plant.
Mura
OBSERVATIONS
3 M's
Muda
Muri
Address material flow issues between asmbly, fabrication, and external to plant.
Review metrics throughout plant on a daily basis.
Perform a monthly safety audit with HSE
/ 2007Complete TASK ACTIONS & FOLLOW-UP
Behave in a safe manner. Maintain housekeeping
Walk Factory Floor before Production meeting
Week Beginning: Complete TASK ACTIONS & FOLLOW-UP
FoldFold
ASQ Presentation v1.ppt 24
Characteristics• Operations leaders - must be
passionate and model the commitment. – Create stretch goals that are radical.– Build the right leadership team
• Coach/develop• Spend time discussing concepts, strategy,
tactics (the Site Steering Team)• Remove the anchors
– Define the few critical objectives.– Create environment where the shop floor
can manage itself.• Support people - must be a zealot.
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ASQ Presentation v1.ppt 25
Recognize people for changing the way they work
Celebrate the JourneyImprovement team luncheon
HOS Star luncheon Personal recognition
ASQ Presentation v1.ppt 26
Be an ambassador of production system
• Embrace Change! Be an “agent of change”. Production system deployment needs your full support and active participation.
• Change your management approach and the organization.• Integrated work planning – Hoshin Planning• Operations is the ultimate internal customer – support it!• Develop and maintain leadership standardized work • Walk the shop floor, respond rapidly, andons, and problem solve • Teach people to train others (OJT). Start with yourself.• You must have observable behaviors that support the spirit and
intent of the production system.• Change the culture!• Involve People• Reach out and impact others (coaching)
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