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TSI Plastics, Inc.
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TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Dec 24, 2015

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Page 1: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

TSI Plastics, Inc.

Page 2: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts and assemblies. TSI specializes in precision CNC machining and injection molding of plastics for a broad range of industries. Specializing in non-metallic materials including Acrylic, Polycarbonate, Nylon, Teflon. TSI helps with both design and engineering services, material selection, and production processes.

o TSI is AS 9100 certified and pursuing SEA Certification to continually improve value to the customer.

o TSI currently has 15 employees

Page 3: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

A kaizen event is a focused improvement activity undertaken by a specially selected team over a short period of time.

An event has three parts:o PreparationoThe event weeko30-day closeout and review

Page 4: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Preparation includes steps 1 -4 Step 1: Select an opportunity for improvement Step 2: Identify the customers’ requirements Step 3: Define the problem Step 4: Collect Data

Page 5: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Clearly an event has to be focused in a very specific area, otherwise it is impossible to achieve significant results in the time available.Events should be focused on:oAreas of significant customer dissatisfactionoHigh levels of wasteoPoor flow

Page 6: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Once the goals and dates have been set, the champion and team leader can go on to develop the remainder of the team contract. This should cover:oWhat will the team look at/not look atoBe clear what is within the scope and what is

noto Is there a separate budget or is it self-financing

Page 7: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

In an event there are two points at which data must be collected:1. Prior to the event to help with the scoping and

preparation2. During the event week to understand the detailed

performance of the current processUse this data to:o Help in the setting of the goalso Brief the team and those affected on the current

situation in the areao Decide what additional data will be needed by the

team and the tools to use during the event week to collect it

Page 8: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

The event week therefore covers steps 4 – 9 of PDCA:

Step 4: Collect Data Step 5: Analyze for root causes Step 6: Find Solution(s) – all the actions that

could be taken to dramatically improve performance

Step 7: Develop a plan to implement solution(s) – this is very quick; the emphasis in on ACTION

Step 8: Implement solution(s) – ACTION – quickly! Step 9: Monitor results and evaluate against plan

– even within the week it is usually possible to measur some of the benefits achieved.

Page 9: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

The aims of the Lean module when used in an event are to:o Understand the main principles and benefits of Lean Enterpriseo Be familiar with the main tools and techniques and their role in

achieving Lean Enterpriseo Understand the role of events in implementing Lean Enterprise

The Lean module is therefore a vehicle to get across to the event team what Lean Enterprise is about; what it involves and why it is important to the business

Page 10: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Before launching into the data collection, etc., it is important to spend some time clarifying what has to be achieved during the week and what this will involve.

The briefing should last no more than one and a half hours and should cover:o Goals and boundarieso Overall time plano Ground ruleso Safety ruleso Visit to the areao Review of existing datao Root causes

Page 11: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Start on-time Say what you are thinking Everyone participates Make and meet commitments No phones or pagers No such thing as a stupid question Discussions stay in the room until it is over Have fun!

Page 12: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

In order to keep control over the week, given the rate of the activity, it is very important to have regular reviews:oWith the team members to check on progress and

agree next stepsoWith the champion to report actions and get

approval where needed. Each of these is considered in turn.

Page 13: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

By the end of day 4, the major actions should have been taken, along with several small steps and a clear plan developed showing what else needs to be done to complete the changes.

The morning of day 5 is spent:o Preparing and delivering a presentationo Deciding the 30 day closeout actionso Reviewing the event week and team performanceo Pulling together a visual display for the event area

The event presentation is made mid-afternoon.

Page 14: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

Purpose To report

o What has been doneo What has been achievedo What else needs to be done to make it sticko What has been learned

Audienceo Sponsor (and possibly other members of the management team).o Others working in the event area.o Supporters.o Other guests.

Lengtho Aim for 30 minutes maximumo Be energetic and focused, do not let it drag

Page 15: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

o Decreased lead time by 60% which converts into a $16,000/month cash flow improvement.

o Decreased WIP by installing a finished goods supermarket. This resulted in a cash flow improvement of $91,000 per year.

o Increased productivity by 30% in a assembly work cell which resulted in a savings of $30,000 per year.

Page 16: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

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Page 17: TSI Plastics, Inc.. o TSI Plastics has been servicing the Aerospace & Defense Industries since 1959 as a contract manufacturer of custom fabricated parts.

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