5S Kiazen in Lami 2

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5S Kiazen in Lami 2

• 02/10/05

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Team members

• Nicole Martinez co leader - Sales
• Joanne Genovese co leader - Laminating
• Lisa Welsh Purchasing
• Donna Funk QA
• Larry Nagy Bending
• JR Slifer Cutting
• Fred Carlson Shipping
• Leanna Stafford - Laminating

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Project Scope

• Staging area for Lami 2
• Washer area feeding Lami 2 assembly
• Lami 2 assembly area
• Soldering station
• Storage cabinet
• Spallshield cutting area

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Project Goals

• Reduce change over by 30
• Increase productivity 25
• Improve 5S audit score by 10
• Introduce at least 1 safety improvement

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Current conditions

• Made arrow diagram of current layout
• Observed processing of 80157
• Observed change over of 80497 to flat armor

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Improvements

• Organized tools, logo screens and templates used
  at washer station outside Lami room
• Established red tag area
• Updated work instructions
• Created visual training aids
• Organized supply cabinet
• Increased 5S audit score
• Redesigned assembly layout and method
• Created new template design

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Before L2 washer table
After L2 washer table
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Newly created red tag area
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Before, Lami 2 assembly area
After, Lami 2 assembly area
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Before, supply cabinet
After, supply cabinet
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After, Lami 2 soldering area
Before, Lami 2 soldering area
i
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Results

• Reduced change over from 28 min to 15 min
• Improved productivity 3.4 pcs per hr to 5.5
• 5S audit score increased from 41 to 72 out of 80
• Safety improvements
• Reminder signs to put protective tape on fingers
• Taped floor in front of electrical panel
  maintaining 36

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Goals Results

• 46
• 62
• 75

• Change over 30
• Productivity 25
• 5S Audit 10

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Remaining task list

• Construct supply cabinet rack (JR due 3/10/05)
• Move curtain inside L2 (Joanne 2/18/05)
• Organize templates (Lisa 3/10/05)
• Limit amount of sticker on flat armor (Larry
  3/10/05)
• Paint lines on floor (Fred 3/10/05)
• Complete sanding work area (Joanne 3/10/05)
• Complete rework area (Leanna 2/17/05)