Quality & Continuous Improvement Management
Semi-annual results report
Index
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1 · VSMComparisson and summary from February to June
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2 · 6´sSummary and new strategies for monitoring
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3 · Flash redutionProject status and improvements obtained
1Value Stream Mapping
June 2023The value stream map is a snapshot of the current state of the organization that includes improvement projects, key performance indicators, and manufacturing and support processes for the organization.
VSM Old 2023
Improvements
- 48 days to produce a mold (7 Weeks)
- 18 improvement projects implemented to reduce lead time
- Digital Twin Development
VSM New 2023
Improvements
- Lead time reduction (4.5 weeks) 32 Days
- Reduction of time between processes (12 days)
- Integration of 16 new improvement projects
2. 6´s (Update)
Results Jan-Jun 2023The 6's methodology is a pillar of the Toyota production system focused on organizing work spaces to optimize operations and reduce transportation waste, search and avoid errors in the processes.
Molding Event
6´s Action Plan
Day 1.- theoretical presentationKey concepts are introduced and reinforced
New SatrategyIt is proposed to start a new kaizen event focused on 6's to improve aspects of order and cleanliness in Molding derived from the lack of attention and discipline of the team
Day 2.- Process of Organizing and classifying
Sort and classify machine drawers
New routesTours by management and leaders are integrated on Tuesdays of each week to improve follow-up to 6's reports
Day 3.- Cleaning and standard
The areas are cleaned and a new 5's standard for machines is defined
Day 4.- Closing and monitoring of standard
The kaizen event is closed and recognition is given to the best employees in following the program
6´s reportFollow-up continues (weight from senior managers to operators) to the 6's report generated by management in conjunction with Quality
3. Flash reduction
Project StatusFlash reduction project update on new molds
Chronology
May 2023
June 2023
July 2023
August 2023
April 2023
Definition of baseline and multidisciplinary team
Standardization of strategies and review of machines
In-depth maintenance of CNC machines to eliminate variation
Initiation of tests with Test block to collect data on strategy and machines
Review of improvements implemented
Result
Machinig CNC Finish CutThe results obtained after the improvements in strategies show positive advances in machining.
75%
213%
Standardization of strategies (4-2)
Cpk improvement vs baseline (0.22-0.47)
60%
Decreased points out of specification (+/- 0.002")
Programming standardization
1. Problem: Programmers do not use the same strategy to program and it causes differences in machining
2. Affected: HSM / Spotting / Molding / Corrections 3. Improvement: Standardization of strategies to minimize errors in machining 4. Benefits: Reduction of variation in machining due to the effects of inadequate strategies
Block V for pillars
1. Problem: Very long column turning time (+4" diameter)2. Affected: PAIG3. Improvement: A device (block V) is created to machine pillars of that dimension in 2D 4. Benefits: Machining time reduction 75%
Machining precision improvement
In process
Gague for Eyebolt
1. Problem: problems in ropes for cargo eyebolts2. Affected: PAIG / 2D3. Improvement: TGauges for eyebolt ropes are created 4. Benefits: Reduction of work in return to correct ropes in 2D
In process
Probe report for references (FCS)
1. Problem: Outdated machining due to taking different references2. Affected: All CNC machining / Mold Making3. Improvement: Testing information is integrated for all side, front and rear references of the mold 4. Benefits: Reduce machining displacement between operations and CMM
Calendar for spotting press
1. Problem: Lack of programming and delays in spotting presses2. Affected: Mold making3. Improvement: A module is created in the ITM App application to schedule the use of spotting presses 4. Benefits: Better management of spouting presses
Elimination of bottlenecks due to disorganization for its use
In process
Supplier evaluation
1. Problem: Provider assessments with excess hours at time of data collection
2. Affected: Purchases
3. Improvement: Creation of a form in smartsheet and database for joint evaluation of suppliers (almacen/kitting/incomng)
Creation of score card for suppliers
4. Benefits: More effective evaluation, reducing information gathering time and providing score cards for strategic suppliers
Overstock reduction
1. Problem: Thompson bars with +0.200" of extra material
2. Affected: 2D components tooling 3. Improvement: Reduction of overstock to 0.050" 4. Benefits: Decreased facing time by 75% Increased insert useful life by 50%
Procedure to avoid Rust
1. Problem: Molds at risk of corrosion due to prolonged storage time2. Affected: Customer3. Improvement: Protection procedure for molds is adopted 4. Benefits: Reduction of molds with rust due to corrosion
Resin traceability (ERP)
1. Problem: Lack of monitoring in traceability of resins2. Affected: Molding / Warehouse / Incoming / Quality / Materials3. Improvement: A module is created to manage inputs and outputs of resins (in development) 4. Benefits: more controlled production process
Improved management of resins for warehouse
Improvement of resin management in mezannine
Kiosks for quick changes
1. Problem: High common tool change time due to transfer to Tooling2. Affected: HSM / 2D / Components3. Improvement: Kiosks are created with previously loaded tools for quick change at the foot of the machine 4. Benefits: 30% reduction in common tool changes
In process
Improved clamping on CNC lathe
1. Problem: Excessive runout and machining times on parts greater than 6" in length (Puma Lathe)2. Affected: Components 2D3. Improvement: A new set of jaws is designed to improve part clamping 4. Benefits: Reduction of runout in clamping
improvement of machining times due to increased revolutions
In process
Inventory of steels (round)
1. Problem: Loss of steel due to lack of control
2. Affected: Warehouse / Purchasing 3. Improvement: A database with automatic codes is created to manage steel inventory 4. Benefits: Better control of steel and reduction of losses
In process
AnalysisTest of new insert
1. Problem: Low insert life time and poor performance2. Affected: Tooling / 2D Components3. Improvement: Tests and analyzes are carried out with new inserts (to define new insert) 4. Benefits: 75% reduction in cycle time in machined parts
Improved useful life by 400%
Superior performance finish
COnitnuous Improvement 2023
Antonio Olan
Created on July 24, 2023
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Transcript
Quality & Continuous Improvement Management
Semi-annual results report
Index
4 · Escribe un títuloLorem ipsum dolor sit amet, consectetuer adi.
1 · VSMComparisson and summary from February to June
5 · Escribe un títuloLorem ipsum dolor sit amet, consectetuer adi.
2 · 6´sSummary and new strategies for monitoring
6 · Escribe un títuloLorem ipsum dolor sit amet, consectetuer adi.
3 · Flash redutionProject status and improvements obtained
1Value Stream Mapping
June 2023The value stream map is a snapshot of the current state of the organization that includes improvement projects, key performance indicators, and manufacturing and support processes for the organization.
VSM Old 2023
Improvements
VSM New 2023
Improvements
2. 6´s (Update)
Results Jan-Jun 2023The 6's methodology is a pillar of the Toyota production system focused on organizing work spaces to optimize operations and reduce transportation waste, search and avoid errors in the processes.
Molding Event
6´s Action Plan
Day 1.- theoretical presentationKey concepts are introduced and reinforced
New SatrategyIt is proposed to start a new kaizen event focused on 6's to improve aspects of order and cleanliness in Molding derived from the lack of attention and discipline of the team
Day 2.- Process of Organizing and classifying Sort and classify machine drawers
New routesTours by management and leaders are integrated on Tuesdays of each week to improve follow-up to 6's reports
Day 3.- Cleaning and standard The areas are cleaned and a new 5's standard for machines is defined
Day 4.- Closing and monitoring of standard The kaizen event is closed and recognition is given to the best employees in following the program
6´s reportFollow-up continues (weight from senior managers to operators) to the 6's report generated by management in conjunction with Quality
3. Flash reduction
Project StatusFlash reduction project update on new molds
Chronology
May 2023
June 2023
July 2023
August 2023
April 2023
Definition of baseline and multidisciplinary team
Standardization of strategies and review of machines
In-depth maintenance of CNC machines to eliminate variation
Initiation of tests with Test block to collect data on strategy and machines
Review of improvements implemented
Result
Machinig CNC Finish CutThe results obtained after the improvements in strategies show positive advances in machining.
75%
213%
Standardization of strategies (4-2)
Cpk improvement vs baseline (0.22-0.47)
60%
Decreased points out of specification (+/- 0.002")
Programming standardization
1. Problem: Programmers do not use the same strategy to program and it causes differences in machining 2. Affected: HSM / Spotting / Molding / Corrections 3. Improvement: Standardization of strategies to minimize errors in machining 4. Benefits: Reduction of variation in machining due to the effects of inadequate strategies
Block V for pillars
1. Problem: Very long column turning time (+4" diameter)2. Affected: PAIG3. Improvement: A device (block V) is created to machine pillars of that dimension in 2D 4. Benefits: Machining time reduction 75% Machining precision improvement
In process
Gague for Eyebolt
1. Problem: problems in ropes for cargo eyebolts2. Affected: PAIG / 2D3. Improvement: TGauges for eyebolt ropes are created 4. Benefits: Reduction of work in return to correct ropes in 2D
In process
Probe report for references (FCS)
1. Problem: Outdated machining due to taking different references2. Affected: All CNC machining / Mold Making3. Improvement: Testing information is integrated for all side, front and rear references of the mold 4. Benefits: Reduce machining displacement between operations and CMM
Calendar for spotting press
1. Problem: Lack of programming and delays in spotting presses2. Affected: Mold making3. Improvement: A module is created in the ITM App application to schedule the use of spotting presses 4. Benefits: Better management of spouting presses Elimination of bottlenecks due to disorganization for its use
In process
Supplier evaluation
1. Problem: Provider assessments with excess hours at time of data collection 2. Affected: Purchases 3. Improvement: Creation of a form in smartsheet and database for joint evaluation of suppliers (almacen/kitting/incomng) Creation of score card for suppliers 4. Benefits: More effective evaluation, reducing information gathering time and providing score cards for strategic suppliers
Overstock reduction
1. Problem: Thompson bars with +0.200" of extra material 2. Affected: 2D components tooling 3. Improvement: Reduction of overstock to 0.050" 4. Benefits: Decreased facing time by 75% Increased insert useful life by 50%
Procedure to avoid Rust
1. Problem: Molds at risk of corrosion due to prolonged storage time2. Affected: Customer3. Improvement: Protection procedure for molds is adopted 4. Benefits: Reduction of molds with rust due to corrosion
Resin traceability (ERP)
1. Problem: Lack of monitoring in traceability of resins2. Affected: Molding / Warehouse / Incoming / Quality / Materials3. Improvement: A module is created to manage inputs and outputs of resins (in development) 4. Benefits: more controlled production process Improved management of resins for warehouse Improvement of resin management in mezannine
Kiosks for quick changes
1. Problem: High common tool change time due to transfer to Tooling2. Affected: HSM / 2D / Components3. Improvement: Kiosks are created with previously loaded tools for quick change at the foot of the machine 4. Benefits: 30% reduction in common tool changes
In process
Improved clamping on CNC lathe
1. Problem: Excessive runout and machining times on parts greater than 6" in length (Puma Lathe)2. Affected: Components 2D3. Improvement: A new set of jaws is designed to improve part clamping 4. Benefits: Reduction of runout in clamping improvement of machining times due to increased revolutions
In process
Inventory of steels (round)
1. Problem: Loss of steel due to lack of control 2. Affected: Warehouse / Purchasing 3. Improvement: A database with automatic codes is created to manage steel inventory 4. Benefits: Better control of steel and reduction of losses
In process
AnalysisTest of new insert
1. Problem: Low insert life time and poor performance2. Affected: Tooling / 2D Components3. Improvement: Tests and analyzes are carried out with new inserts (to define new insert) 4. Benefits: 75% reduction in cycle time in machined parts Improved useful life by 400% Superior performance finish