Aug MA 5S and Visual Management - mfrall.com · Carl Zeiss Industrial Metrology , LLC, Dale Williams, Production 2016-08-11 51 5S and Visual Management Flags • Green flags are used

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Good Morning!

Manufacturers AllianceSharing Education & Resources Peer-to-Peer

Welcome

Kirby Sneen, Vice President

Manufacturers Alliance

Please silence your phones during the

presentations and discussion.

A PDF copy of today’s

slides will be sent to you after the event.

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Thank you to our host

Thank you members

Member Companies may send up to five employees to Educational Seminars and Webinars at no cost.

Bauer Welding and Metal Fab Boston ScientificCentral Package and Display DDL Inc.Dynamic Group Electric MachineryFlexmation Inc. Force AmericaGeneral Dynamics Graco Inc.Heraeus NeoMetrics Imperial Plastics Inc.JEM Technical Liberty Carton CompanyLifeHealth LLC Medtronic Inc.Metal Craft Machine Midwest Rubber Service and SupplyMikros Engineering Inc. Millerbernd ManufacturingMOCON Inc. Modern MoldingNystrom Inc. Olympus Surgical TechnologiesPrecision Associates PGCProMed Molded Products REO PlasticsReviva Synergy HealthTurck Inc. Tillges Certified Orthotic ProstheticUpsher-Smith Labs Vista Outdoor

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Member Resources

2016 Wage Survey 207 company participants, 175+ positions included

Available to purchase now

Job Postings & Resume Listings Skilled, Technical, and Management positions, 350+ views per day

Members may post openings at no cost

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Doug Sparks

• Owner/Operator of 4 separate businesseso 2 of which are dealing directly with World Class

Manufacturers.

• 30+ years of operational experience o Common sense approacho Highly effective results.

• Over 500 separate facilities and 10,000+ peers, trained

• Shingo Prize Recipient

• 2004 Manufacturer of the Year

• Several Patents

What is Value Added?

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What is Value Added?

Direct Bolt Every joint used by Flex Craft features the use of 5/16”

bolts.

Universal Joint

How does it work?

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Questions? Visit our display after today’s event

What’s your idea?

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Phone: 1‐877‐565‐3539

Email: info@flex‐craft.com

www.Flex‐Craft.com

Moderator

Jeff Meyer-Quarberg,

Principal Process Improvement Analyst

Boston Scientific

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Millerbernd Manufacturing

Eric Quast

Emily Lewerenz

Continuous Improvement Technicians

Agenda:• History • Ring and cylinder division

• 5S• Visual Management

• Pole Division• Visual Management

• Wrap up

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600K Sq. Ft. / 350 Employees / 55 Acres

Millerbernd Manufacturing Company

622 6th Street SouthWinsted, MN 55395

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Ring and Cylinder Division

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5S

5S

• Issues

• Mission

• How?

• TPM (Total Preventative Maintenance)

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5S

• Standard work in place

• Metrics and Visual Queues

• Sustainment

5S

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Visual Management

• Issue

• Mission

• How?

• Start of Process

Sales order log

Visual Management

• Flag Visual

• Information tracking

• Std. Work

Sales order

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Visual Management

• MRS (Material Replenishment System)

• Shop Ownership

Pole Division

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2 years ago

• 6-8 week lead time• Order status• Some orders 6-7 weeks

past due• No consistency (cherry-

picking)• “top 30” List• Focus changed daily• Abundance of Job

Orders on the shop floor

• Batch Processing

What did we do about it• Admitted that we had

a problem

• Held a week long event• Needed a system that

was simple yet effective

• Needed to sync up all areas of production

• Included all players in the process

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Event Results

• Daily Pitch Scheduling!

• 3 week rotating schedule

• Job Orders printed when needed

• Main Production Board

Challenges to Implementation

• Resistance to 1-piece flow from batching

• Stock to Make (inventory system)

• Increase in paperwork

• Communication

• Team Scheduling

• Updating the board

• Accounting for attributes

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Visual Area Boards

• Area status at a glance

• Updated by operators in the area

• Tracked by leads

• Checked by management

• accountability

Successes• 3 week lead time in

the shop

• Easy tracking of order status

• Team communication at daily production meetings

• Controlled WIP

• Changes handled with ease

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Thank You!

Carl Zeiss Industrial MetrologyDale Williams,

Production Manager

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5S and Visual Management

Boston Scientific, 2016-08-11

Dale Williams

362016-08-11Carl Zeiss Industrial Metrology, LLC, Dale Williams, Production

Company History

Carl Zeiss AG, is a company founded in 1846 by amechanic of the same name. Known as one of thebest in the field, ZEISS set the bar high formanufacturing in optics. Today Carl Zeiss AG hasa portfolio that covers consumer optics, industrialmetrology, medical technology, microscopy,semiconductor manufacturing technology,spectroscopy, and vision care. While the companyis headquartered in Oberkochen, Germany,facilities from each of the businesses surround theworld. One of those companies is located here inMaple Grove, Minnesota. The facility in Minnesotais a branch of the industrial metrology business(metrology is the science of measurements)having approximately five hundred employees, butsupports all of the Americas with its production ofCMM products, as well as the services required tomaintain them.

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Company History


Product Description

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Product Description

A coordinate measuring machine, orCMM, is a machine commonly used inmanufacturing for quality assurancepurposes. This machine, with the helpof a computer and operator, canmeasure the geometric properties of anobject down to the micron level. Amicron is 1/1000 of a millimeter, andcannot be seen with the naked eye.After an object is secured on themeasuring surface of the machine, themachine can use a variety of differingprobe options to take measurements in20K plus positions and compare theresults to required specifications.



Production Board

• A monitor can be found at the end of each product line and is maintained by technicians

• Software developed in house

• Web based

• Communicates with SAP

• Tracks product orders through entire production process

• Information is in real time

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Training Board

• Tracks every technicians proficiencies in various jobs/roles on the production floor.

• Provides visual for both mangers and technicians on progress

• Tracks and visually displays production training plans in a full year view.



CPO/CAPA Board

• Monitors floor wide CPO (customer perfect order) results

• Acts as a tool for monitoring and eliminating active CAPA (corrective action/preventative action) issues

• Managers meet weekly at board to discuss progress

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Production Cell Status Stands

• Displays customer name, work order number, and progress dates for machine being built

• Shows potential risks to CPO (customer perfect order) and its sub metrics OTD (on time delivery), EF (equipment functionality), and OC (order complete)

• Wheel provides production status of the cell and reason if there is a delay.



Stack Lights

• Attached to each work station

• Provides high level visual status of a particular cell

• Easy to see from a distance

• Connected to network

• Provides real time stop/start information to production managers via web page overview, and text message

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Line Board

• Each line has a board where line specific metrics are displayed

• Metrics are displayed in day, week, and month format, showing positive or negative trends

• Other information displayed includes yearly goals, and monthly CPO results

• Production managers manage to these metrics in their morning meetings



Kanban

• Set up in stoplight fashion

• Adjusted by production planners

• Cards print automatically through SAP system when part is scanned empty in warehouse

• Visually cues technician to the parts needs of the warehouse, as well as the urgency at which parts are needed.

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Floor Tape and Color Coded Carts

• Floor taping designates locations and boundaries

• These include:

• Material cart locations• Work cart locations• 6S cart locations• Work cell boundaries• Walking paths/aisle ways• Etc.



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Cart Signs

• All work carts have large signs to assist warehouse personnel in locating carts for two bin system parts refills.



Divider Walls

• Used to designate/divide production line areas

• Dual purpose as they also act as temperature control for machine testing

• Adds a “wow” factor for guest tours

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Flags

• Green flags are used as a visual signal to the shipping department when machines are complete and ready for pickup, bracing, and packaging.



Foam Tool/Fixture Organization

• Foam is used throughout the production floor to organize tools and fixturing

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Conclusions

Break

Take 10 minutes and

meet someone new

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Dynamic Group

Steve Kalina

President

Dynamic Group

5S & Visual Management

Steve Kalina

President

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Origins

•World Class Precision Molds & Molding

•Dynamic Engineering and Dyna‐PlastBrought Together

• Expanded Capabilities

•Dyna‐PlastMolding

•Dynamic Engineering Founded by Dave Kalina & Peter McGillivray

Precision Molds & Molding

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Who we Serve• Niches

• Small• Extremely Complex

• Tight Tolerances• High Throughput

• Industries• Medical• Dental• Defense• High Precision

Medical Device Contract Manufacturing

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Journey to Lean & Continuous Improvement

Developing a Culture

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Core Values

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Continuous Improvement Program

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Why 5s and visual management?

1. Perception is reality

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Perception of Manufacturing

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2. Communication/Team‐work

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2. Communication/Team‐work3. Consistency

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2. Communication/Team‐work3. Consistency

4. Life is easier!

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Lessons Learned

• Begin with Culture

• Find the champions, get their buy‐in and then let them flourish

• Keep it Simple

• Start with small changes. Hundreds of little impacts driven by many will usually drive more long‐term success than a few large changes driven by a few

• Get Started!

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Thank you!

Steve KalinaPresidentDynamic Group, [email protected]‐792‐1278

Q & ACarl Zeiss IMT Dale Williams

Millerbernd

ManufacturingEric QuastEmily Lewerenz

Dynamic Group

Steve KalinaModeratorJeff Meyer-Quarberg

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How did we do?

Please fill out your feedback sheet for today’s seminar.

Seminars & WebinarsModern Day Kaizen EventsWebinar August 19 online or Live at Manufacturers Alliance in Golden Valley

Performance Metrics With PurposeSeptember 8 at Normandale

Standard Work for SalesOctober 13 at Dunwoody

TPM and Predictive MaintenanceWebinar October 28 online or Live atManufacturers Alliance in Golden Valley

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WorkshopsEngaging Your Workforce in Daily Improvements August 16

Finance and Accounting for Non-Financial Managers Sept 13-14

Lean in Contract ManufacturingSeptember 15

Lean Product DevelopmentSeptember 20

NEW Corrective Action/Preventive Action (CAPA) September 28

NEW Coaching for Continuous Improvement October 4

CertificationsLean Practitioner Certification

Series starts September 7

Supervision Fundamentals CertificationSeries starts September 8

Six Sigma Green Belt Certification Series starts October 5

Lean Leader Certification Series starts October 13

Flyers on the back table!

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See you soon!

Manufacturers Alliancewww.mfrall.com

Aug MA 5S and Visual Management - mfrall.com · Carl Zeiss Industrial Metrology , LLC, Dale Williams, Production 2016-08-11 51 5S and Visual Management Flags • Green flags are used

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