20425 Utica Tugger

Acuity Business SystemAcuity Business SystemAcuity Business SystemAcuity Business System

Material Handling Kaizen Report OutTugger Delivery

Utica

April 25, 2008


Team

Kathryn Sardini, Diana Ronan, Doug Tegtmeier, Toby Justice, Chris Lucas, Andy Scott (Team Leader)Kathryn Sardini, Diana Ronan, Doug Tegtmeier, Toby Justice, Chris Lucas, Andy Scott (Team Leader)


CharterBusiness Case:

TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $1.65 The purpose of the event is to establish Standard Work using a Tugger system to pick up and deliver needed materials to the Assembly cells. Currently, each group of cells has a Material Handler servicing only those cells. The Tugger will pick up and deliver materials to all Assembly cells on a regular route.

Business Case:

TVC a KPI for the Utica plant. The TVC goal is $143. The implementation of the Tugger System will improve TVC by $1.65 The purpose of the event is to establish Standard Work using a Tugger system to pick up and deliver needed materials to the Assembly cells. Currently, each group of cells has a Material Handler servicing only those cells. The Tugger will pick up and deliver materials to all Assembly cells on a regular route.


Charter


Target SheetTarget Sheet

Location: Utica Start date: 4/21/08

Value stream: Assembly Finish date: 4/25/08

Process: Takt Time:

Kaizen: Tugger

Start Target Day 1 Day 2 Day 3 Day 4 ResultChange

Rate

Travel Distance (Feet) 57456 38304 57456 57456 57456 36408 36408 -37%

Crew Size 6 4 6 6 6 4 4 -33%

0 0%

0 0%

0 0%

•Day 4 the 4 water spiders supported assembly with material not located in the supermarket and the tugger driver supported assembly requirements with material located in the supermarket.

•Standard work shows that if all material used at the cells were located in the supermarket the tugger would not need any assistance from water spiders to support all 12 cells which is a 77% reduction in travel time regardless of production volume.

•Day 4 the 4 water spiders supported assembly with material not located in the supermarket and the tugger driver supported assembly requirements with material located in the supermarket.

•Standard work shows that if all material used at the cells were located in the supermarket the tugger would not need any assistance from water spiders to support all 12 cells which is a 77% reduction in travel time regardless of production volume.


Standard Work Elements

Work Elements

0.6 Seconds Each step the tugger operator takes (2.5 feet per step)

3.66 Feet per Seconds Tugger Travel Time estimated 2.5 miles per hour

3.9 Seconds Get on tugger

3.9 Seconds Get off tugger

7 Seconds per container Deliver container/ Pick up empty


Standard Work Calculation

PART#STANDARD

PACKPIECES PER

UNIT Daily UsageDaily Total

Usage# of containers

per day# of containers

per hour

# of containers per hour * 7 secs

per container (pickup/delivery)

GA-1054 50 1 72 72 1.4 0.2 1.4

SC-2951 100 2 72 144 1.4 0.2 1.4

SC-989 100 2 72 144 1.4 0.2 1.4

SC-641 200 2 72 144 0.7 0.1 0.7

SC-2944 100 2 72 144 1.4 0.2 1.4

SC-456 1000 5 72 360 0.4 0.0 0.3

MI-3054 200 3 72 216 1.1 0.1 1.0

93.1+7.8+54 sec.Total=154.9 sec. (93.1sec. delivery and pick up of empty

bins + 7.8 sec. to get on and get off tugger + walk time around cell)

Total=154.9 sec. (93.1sec. delivery and pick up of empty bins + 7.8 sec. to get on and get off tugger + walk time

around cell)


Standard Work CalculationDelivery Route Standard Work

Stop ID Action Stop Time Drive Time

1Travel from stop 7 at market to first stop 8.

Deliver parts, pick up empty containers and pull signals 181.2 30.1

2 Travel from stop 8 to stop 9.Deliver parts, pick up empty containers and pull signals 152.8 13.1



5 Travel from stop11 to stop 12.Deliver parts, pick up empty containers and pull signals 199.7 15.3


7 Travel from stop 13 to stop 1. Return to Market 63.7

8 Travel from stop 1 to stop 7 Market Time 54.4

Total: 21 3.6

Total Delivery Route Time: 24 min. 36 sec. per hour


Time StudyDelivery Route Standard Work

Stop ID ActionStop Time Actual Time Variance Drive Time Actual Time Variance

1Travel from stop 7 at market to first stop 8.

Deliver parts, pick up empty containers and pull signals 181.2 68.3 112.9 30.1 31.0 -0.9

2Travel from stop 8 to stop 9.

Deliver parts, pick up empty containers and pull signals 152.8 144 8.8 13.1 14.0 -0.9




Deliver parts, pick up empty containers and pull signals 154.9 517 -362.1 14.8 17.0 -2.2

5Travel from stop11 to stop 12.



Deliver parts, pick up empty containers and pull signals 390.8 150 240.8 12.3 12.0 0.3

7Travel from stop 13 to stop 1. Return to Market 63.7 57.0 6.7

8Travel from stop 1 to stop 7 Market Time 54.4 54.4 0.0

Total: 21 18 3 3.6 3.7 -0.1

Total Delivery Route Time: 24 min. 36 sec. per hour


1 Hour Coupled Route Parameters

Actual

Max load time 33% of total time

20 min. (0.33 x 60 min.) Under 20 min.

Max travel time 33% of non load time

13 min. 12 sec. (.33 x 40 min.) 3 min. 36 sec.

*If load time were less than 33% (20 min.), maximum travel time could be greater.

Total Stop Time

27 min. available if travel time is 13 min. 12 sec. 21 min.

Total Time 1 hr. 1 hr. 44 min. 36 sec.


Kaizen Title

Next page Next page

Operator No. Problem Measures Taken Results

Remarks

Name

Kaizen Sheet

1.1. No Defined Delivery Route. Marshaller’s took random routes.

No Defined Delivery Route. Marshaller’s took random routes.

Defined Tugger Route and added delivery

stops.

Defined Tugger Route and added delivery

stops.

Reduced travel distance by 37%

(reduction of 4 miles in walking distance).

Reduced travel distance by 37%

(reduction of 4 miles in walking distance).

A spaghetti diagram showed that one marshaller for one out of the 12 cells walked 9575 feet = 1.8 miles of walk distance. (1.8*12= 21.5

miles)

A spaghetti diagram showed that one marshaller for one out of the 12 cells walked 9575 feet = 1.8 miles of walk distance. (1.8*12= 21.5

miles)

13104 feet (2.5 miles) of travel distance for all 12 cells.

13104 feet (2.5 miles) of travel distance for all 12 cells.




Kaizen Title

Before Kaizen After Kaizen


Remarks

Name

Kaizen Sheet

2.2.There were items not on the tugger

route.

There were items not on the tugger

route.

Added one of the items to the

supermarket.

Added one of the items to the

supermarket.

Spacers are now on the tugger route.

Spacers are now on the tugger route.


Kaizen Title

After Kaizen After Kaizen


Remarks

Name

Kaizen Sheet

3.3.Not all lines had empty bin return

chutes.

Not all lines had empty bin return

chutes.

Installed 26 empty bin return chutes

throughout assembly.

Installed 26 empty bin return chutes

throughout assembly.

Each cell has a way to signal the

replenishment of their empty totes.

Each cell has a way to signal the

replenishment of their empty totes.


Kaizen Title



Remarks

Name

Kaizen Sheet

4.4.

10% of items in the part presentation racks do not

have permanent locations because of high variation (i.e. sockets).

10% of items in the part presentation racks do not

have permanent locations because of high variation (i.e. sockets).

Developed a kitting procedure for the high

variation items.

Developed a kitting procedure for the high

variation items.

Now tugger will have a replenishment signal.

Now tugger will have a replenishment signal.


Kaizen Title



Remarks

Name

Kaizen Sheet

5.5.Used forklifts, walk behind

forklifts, and push carts (Safety issues, inefficient

material movement methods).

Used forklifts, walk behind forklifts, and push carts

(Safety issues, inefficient material movement

methods).

Starting using a tugger vehicle that pulls a

string of carts.

Starting using a tugger vehicle that pulls a

string of carts.

Optimal material delivery method.Optimal material delivery method.


Kaizen Title

After Kaizen After Kaizen


Remarks

Name

Kaizen Sheet

6.6.No defined address

system or visual controls.

No defined address system or visual

controls.

Added visual signs above each part

category and rack level indicators.

Added visual signs above each part

category and rack level indicators.

Easier to find material.Easier to find material.


Report Card/Newspaper


Report Card/Newspaper


Questions?

20425 Utica Tugger

Documents

total stop time

seconds tugger travel

total time

max travel time

maximum travel time

market time

id action stop time

walk time