Work Measurment Casestudy
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Texas Center for Applied Technology
Work Measurement and Process at a Glance in Lean (A case study at the Corpus Christi Army Depot by Texas A&M Engineering) Harry S. Whiting II, MSIE Fred Canales, BSIE Dr. J. J. Congleton, PhD, CPE, PE
1 - TEES/CCAD Proprietary Information
Lean Process Texas Center for Applied Technology
• Preparation for Lean Event • Value Stream Analysis • Prep work for process analysis
• Lean Event • Verify correct process • Eliminate NVA steps
• Future State • Process At A Glance • Run the new process to verify • Implement 2 - TEES/CCAD Proprietary Information
Lean Process (Preparation) Texas Center for Applied Technology
• Value Stream Analysis • Value Stream Map w/ areas of opportunity • TAKT Time calculations
• Prep work for process analysis • Observe and record process • Create Process Map • Layout & Spaghetti Chart • Sort data (VA, NVA, NVAN, Wastes) 3 - TEES/CCAD Proprietary Information
TAKT Time Texas Center for Applied Technology
• TAKT is a German word meaning Beat • Producing to the pace of customer demand (no faster, no slower). • TAKT time = Available time/Customer Demand
4 - TEES/CCAD Proprietary Information
Calculating TAKT Time Texas Center for Applied Technology
Typical TAKT Time Calculation: 991 units = 82.5 units per month 12 months 82.5 = 4.12 units per day = 4 units per day 20 days/month 15 Hrs (2 Shifts) = 3.63 TAKT Time 4.12 5 - TEES/CCAD Proprietary Information
Identify Problem Areas Texas Center for Applied Technology
Observation Time vs. TAKT Time 8
7.32
7 6
5.41
5 4 TAKT 3.63
3 2 1 0 OBSERV. # 1
OBSERV. # 2
6 - TEES/CCAD Proprietary Information
Observe process Texas Center for Applied Technology
Time observations on the shop floor 7 - TEES/CCAD Proprietary Information
Time Observation Texas Center for Applied Technology
• Best way to see waste. • Real facts and data about the operation. • Non-Value added waste is seen in detail.
8 - TEES/CCAD Proprietary Information
Std Work Combination Sheet Texas Center for Applied Technology
New / Revison
________
Organization
Page Work Center
_______
of
Supervisor Time
Step #
Secs.
Process Description
* Start time/date (see notes)
2 Hours
Min.
Value Added manual
auto
_______
Product Line
Standard Work Combination Sheet Part Number
Customer Demand units Available Time
Days
Non-Value Added manual
Date _____________
Operator
travel
queue
Part Name
units
Takt Time
mins.
mins.
sub-total for ref. Start VANVA 0 20 time 40
1
0
0
2
0
0.0
3
0
0.0
4
0
0.0
5
0
0.0
6
0
0.0
7
0
0.0
8
0
0.0
9
0
0.0
10
0
0.0
11
0
0.0
12
0
0.0
13
0
0.0
14
0
0.0
15
0
0.0
16
0
0.0
17
0
0.0
18
0
0.0
19
0
0.0
20
0
0.0
60
80
100
120
140
160
180
200
Notes: Password: stdwork (1 sheet per person)
TOTALS:
VA
NVA
% VA
0
0
#DIV/0!
Secs. format shall be in "hh:mm:ss" + "a/p". i.e. 6:30:25 p Mins. & Hrs. format shall be in "hh:mm" + "a/p". Days format shall be in base numerical format
9 - TEES/CCAD Proprietary Information
220
Work Measurement Texas Center for Applied Technology
• Work measurement is studying a task and breaking it down into elements for analysis. • Texas A&M Engineering does two types of Work Measurements at CCAD • Time Standards: Full breakdown of all work elements • Personal, fatigue and unavoidable delays (PF&D) • Pace rating • Time Observations: Concentrate on waste elements in study 10 - TEES/CCAD Proprietary Information
Time Standard Sheet-Summary Texas Center for Applied Technology
STD. DATA ANALYSIS/APPLICATION OPERATION: PTO (Observation #2) SUPERVISOR: MECHANIC(S): ANALYST(S): # PROCESS SUMMARY A Preperation B Clean PTO gearshaft in varisole booth C Install damper ring onto PTO gearshaft D Apply label to bearing E Sandblast part number onto PTO gearshaft F Install bearing onto PTO gearshaft G Perform backlash test on PTO gearshaft
11 - TEES/CCAD Proprietary Information
IN
OUT 630 160 122 122 662 222 180
DATE: SHOP: OP-CODE: EIC/WPC: NORMAL TIME (min) 23.90 7.68 7.57 19.45 16.03 12.90 24.90
Observation Work Sheet-Detail Texas Center for Applied Technology
STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: Output Shaft SUPERVISOR: MECHANIC(S): DISTANCE ANALYST(S): # Job Description IN OUT A Preperation 1 Go to inventory bins to get parts 50 2 Gathering all parts needed 3 Go to workbench 50 4 Take parts out of bin 5 Verify numbers match for housing 6 Verify numbers match for rotating seal and output shaft 7 Verify numbers match for bearing (1 of 2) 8 Verify numbers match for bearing (2of 2) 9 Go to QC table 20 10 Sell bearings 11 Go to workstation 20 12 Open package of common hardware 13 Clean common hardware 14 File down transfer tube 15 Inspect bearings (inspector) 16 Consult with inspector 17 Put away paperwork Subtotal 140 B 1 2 3 4 5 6 7 8 9 10
Prepare bearings for oven Open O-ring package Install O-rings onto transfer tube and jets Oil up 2 jets and install in housing Go to parts bin (get piston rings) Get piston rings Go to workbench Install piston rings on housing Measure bearings (micrometer) Place hardware onto bearings (to put in oven) Measure rotating seal (micrometer)
46
CATEGORIES DATE: O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: T: Transport/GatheR: Rework PR:Operation NVEIC/WPC: Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. Pr Eng. 0 0 1 1 2 5 8 14 16 16 17 17 18 21 22 23 24
0 27 28 43 10 50 24 45 28 35 25 33 30 7 30 30 20
0 1 1 2 5 8 14 16 16 17 17 18 21 22 23 24 25
27 28 43 10 50 24 45 28 35 25 33 30 7 30 30 20 21
T PR T PR I I I I T I T PR CNVA O I I PR
0.45 1.02 0.25 0.45 3.67 2.57 6.35 1.72 0.12 0.83 0.13 0.95 2.62 1.38 1.00 0.83 1.02
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0.45 1.02 0.25 0.45 3.67 2.57 6.35 1.72 0.12 0.83 0.13 0.95 2.62 1.38 1.00 0.83 1.02 25.35
25 26 27 29 29 30 30 31 32 33
21 43 42 40 55 3 17 23 57 22
26 27 29 29 30 30 31 32 33 34
43 42 40 55 3 17 23 57 22 24
PR O O T T T O I O I
1.37 0.98 1.97 0.25 0.13 0.23 1.10 1.57 0.42 1.03
1 1 1 1 1 1 1 1 1 1
1.37 0.98 1.97 0.25 0.13 0.23 1.10 1.57 0.42 1.03
12 - TEES/CCAD Proprietary Information
Identify Flow Texas Center for Applied Technology
Induct Part
STORAGE GOOD
Evaluation
MACHINE SHOP
NDT Shop
CLEANING SHOP
Component Assembly
WELDING SHOP
BAD
MACHINE SHOP
PLATING SHOP
METAL SPRAY
MACHINE SHOP
NDT Shop
CLEANING SHOP
Typical Part Flow 13 - TEES/CCAD Proprietary Information
HEAT TREAT
Component Assembly
Finished Product
Spaghetti Diagram Texas Center for Applied Technology
• Purpose: To help see movement of people. • Helps to identify waste of motion and transportation. • You can stand back and see the flow, see the waste.
14 - TEES/CCAD Proprietary Information
Spaghetti Diagram Texas Center for Applied Technology
BEFORE RIE Total Distance 2376 ft. (0.45 miles) AFTER RIE Total Distance 1256 ft. (0.23 miles) Savings of 1120 ft.
15 - TEES/CCAD Proprietary Information
Value-Added Activities Texas Center for Applied Technology
1. Is the customer willing to pay for this activity? 2. It must be done right the first time, every time. 3. The action must somehow change the fit, form, or function of the material being worked.
16 - TEES/CCAD Proprietary Information
Non-Value Added Texas Center for Applied Technology
Activities that take time, material, or space but do not physically change the material. 1. 2. 3. 4. 5. 6. 7.
Defects Overproduction Transportation Waiting Excess Inventory Excessive Motion Non Value-Added Processing 17 - TEES/CCAD Proprietary Information
Lean Analysis Sheet Texas Center for Applied Technology
STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: PTO (Observation #1) SUPERVISOR: MECHANIC(S): DISTANCE ANALYST(S): Job Description IN OUT # 3 Wash PTO gearshaft in booth
DATE: CATEGORIES O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: PR:Operation NVEIC/WPC: T: Transport/GatheR: Rework Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. 13 57 16 22 CVA 2.42 1
3 5 7 6 5 5
Inspect PTO gearshaft (make sure serial # matches) File down gear (double check if gear is good/bad) Inspect PTO gearshaft (good/bad) Inspect serial numbers match (double-checking) Inspect bearing and serial #'s match Sell to inspector
4 7 10 17 43 64
0 0 30 30 43 20
6 7 12 18 44 65
0 44 52 12 12 15
I I I I I I
2.00 0.73 2.37 0.70 0.48 0.92
1 1 1 1 1 1
7 2 7 9 1 2 3
Sandblast stencil onto PTO gearshaft Install damper ring onto PTO gearshaft Install bearing onto PTO gearshaft using press machine Torque bearing onto PTO gearshaft Perform 1st run (backlash test)/ record results Perform 2nd run (backlash test) / record results Perform 3rd run (backlash test) / record results
32 38 44 47 50 53 54
43 30 55 44 8 37 37
33 41 46 50 53 54 56
49 15 25 8 37 37 43
O O O O O O O
1.10 2.75 1.50 2.40 3.48 1.00 2.10
1 1 1 1 1 1 1
7 Paperwork (fill out A&I sheets) 4 Paperwork (stamp A&I sheets)
18 56
12 43
21 64
27 20
P P
3.25 7.62
1 1
1 5 3 4 6 1 3 4
12 16 41 41 44 21 25 27
52 50 15 52 12 27 16 25
13 17 41 43 44 23 27 32
30 30 52 43 55 37 25 3
PR PR PR PR PR PR (SB) PR (SB) PR (SB)
0.63 0.67 0.62 1.85 0.72 2.17 2.15 4.63
1 1 1 1 1 1 1 1
Prepare to wash PTO gearshaft in varisole booth Dry PTO gearshaft Grease up PTO gearshaft Open package for bearing/put on latex gloves Put away paperwork Prepare PTO gearshaft for sandblast (apply tape ) Make stencil for part # and serial # Cut/Tape stencil onto PTO gearshaft
18 - TEES/CCAD Proprietary Information
Categorize/Lean Analysis Texas Center for Applied Technology
PTO Lean Analysis (Obs#1) 16.00
14.33
14.00 11.43
12.00
10.87 10.05
10.00 Tim e (m in)
7.20
8.00 6.00 4.00
4.48
3.50
2.42
2.00 0.00 CV A
In sp ec tio n
Op er ati on
Pa pe rw or k
Tr Pr Tr Pr an ep an ep sp er sp er at at o or r ta ion ion tat t i io on (S n an (S d an Bl d as Bl tin as g) tin g)
Category 19 - TEES/CCAD Proprietary Information
Identify NVA and VA steps Texas Center for Applied Technology
(NVA & VA categories) STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: PTO (Observation #1) SUPERVISOR: MECHANIC(S): ANALYST(S): # Job Description 3 Wash PTO gearshaft in booth 5 File down gear (double check if gear is good/bad) 1 Get paperwork/A&I sheets 2 Go to inventory bin (get PTO gearshaft) 7 Paperwork (fill out A&I sheets) 4 Paperwork (stamp A&I sheets) 5 Dry PTO gearshaft 3 Make stencil for part # and serial # 4 Cut/Tape stencil onto PTO gearshaft 6 Go to inventory bin (get another PTO gearshaft, got a bad one) 2 Go to varisole booth 4 Go to workstation 2 Go to stencil machine 5 Go to sandblast machine 8 Go to workstation 1 Go to inventory bin (get bearing) 8 Go to borrow run-on (used to torque bearing) 4 Get file brush (toolbox) 3 7 6 5 7 1 5 1 6 9 3 4 6
Inspect PTO gearshaft (make sure serial # matches) Inspect PTO gearshaft (good/bad) Inspect serial numbers match (double-checking) Inspect bearing and serial #'s match Sandblast stencil onto PTO gearshaft Prepare to wash PTO gearshaft in varisole booth Sell to inspector Prepare PTO gearshaft for sandblast (apply tape ) Prepare machine for sandblasting Take tape off PTO gearshaft Grease up PTO gearshaft Open package for bearing/put on latex gloves Put away paperwork
IN
DISTANCE OUT
264 122
122 80 80 316 26 320 122 222
CATEGORIES DATE: O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: PR:Operation NVEIC/WPC: T: Transport/GatheR: Rework Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. 13 57 16 22 NVA 2.42 1 7 0 7 44 NVA 0.73 1 0 0 2 20 NVA 2.33 1 2 20 4 0 NVA 1.67 1 18 12 21 27 NVA 3.25 1 56 43 64 20 NVA 7.62 1 16 50 17 30 NVA 0.67 1 25 16 27 25 NVA 2.15 1 27 25 32 3 NVA 4.63 1 8 42 10 30 NVA 1.80 1 13 30 13 57 NVA 0.45 1 16 22 16 50 NVA 0.47 1 23 37 25 16 NVA 1.65 1 32 3 32 15 NVA 0.20 1 33 49 35 28 NVA 1.65 1 37 29 38 30 NVA 1.02 1 46 25 47 44 NVA 1.32 1 6 0 7 0 NVA 1.00 1 4 10 17 43 32 12 64 21 32 35 41 41 44
20 - TEES/CCAD Proprietary Information
0 30 30 43 43 52 20 27 15 28 15 52 12
6 12 18 44 33 13 65 23 32 37 41 43 44
0 52 12 12 49 30 15 37 43 29 52 43 55
NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN
2.00 2.37 0.70 0.48 1.10 0.63 0.92 2.17 0.47 2.02 0.62 1.85 0.72
1 1 1 1 1 1 1 1 1 1 1 1 1
Identify NVA and VA steps Texas Center for Applied Technology
PTO Observation #1
64.28 70.0
60.0
50.0 35.02 40.0
Time (min)
54.47% 30.0 16.03 13.23
20.0 24.94%
20.59% 10.0
0.0 NVA
NVAN
VA
Type of Steps
21 - TEES/CCAD Proprietary Information
TOTAL TIME (MIN)
Pie Chart Texas Center for Applied Technology
Cabinet for Caps 7.7%
Chemicals 2.5%
Hardware 1.8%
Parts Pallet 6.4%
Work Station 39.6%
PSA Table 14.5% Special Tools 6.1% Aircraft 21.5%
22 - TEES/CCAD Proprietary Information
Fishbone Diagram Texas Center for Applied Technology
Pave Hawk Disassembly Fishbone Diagram 3.14 Hours
10.05 Hours
3.45 Hours
PAPERWORK 5.5%
SET UP 17.7%
CLEAN 6.1% Aircraft 40.1%
44.9% Burr Tags
Aircraft 77.1% 1.3% Workstation
26.9% Part
FOD 15.8%
Hardware 8.7%
Workbook 53.6%
0.6% Personal
10.7% Workstation
1.4% Computer
Tools 5.1% Safety Guards 9.5% 4.1% Tools
1.8% Searching
21.5% Aircraft
82.5% Confer & Assist 7.7% Cabinet
2.8% PC Board
WASTE
Chemicals 2.5%
Parts 6.4%
Part 15.6% 0.7% Tool
6.1% Special Tools PSA Table 14.5%
0.5% PSA
Hardware 25.0%
1.8% Hardware Workbook 0.1%
Workstation 39.6%
OTHER 4.6 %
TRAVEL 27.2%
INSPECTION 22.5%
2.62 Hours
15.40 Hours
12.78 Hours
23 - TEES/CCAD Proprietary Information
56.71 Hours
Lean Process (Event) Texas Center for Applied Technology
• Verify Correct Process • Observed work standard • Flow chart or Process Map • Spaghetti Chart
• Analyze and develop ways to eliminate NVA steps for operator or transfer to assistant
24 - TEES/CCAD Proprietary Information
Verify Process Map Texas Center for Applied Technology
25 - TEES/CCAD Proprietary Information
Value Added & Necessary Steps Texas Center for Applied Technology
VA mapping Chart
4.000
3.63
3.500
3.000
2.500
Tim e (hrs) 2.000
1.500
1.000
0.83
0.75
0.500
0.12 0.080.050.17
0.25
0.17 0.12 0.05 0.03 0.08 0.05 0.07 0.020.020.02 0.020.02
0.33
0.25 0.08
21
22
0.07
0.000 1
2
3
4
5
6
7
8
9
10
11
12
13
14
Process Steps
26 - TEES/CCAD Proprietary Information
15
16
17
18
19
20
23
24
Lean Process (Future State) Texas Center for Applied Technology
• Process At A Glance adds visual data to create Future State for operator • Pictures of Parts, Tools, Machines • Kitting • Tool lists • Parts lists • Hardware lists
• Standard Work Instructions
• Run the new process to verify • Implement 27 - TEES/CCAD Proprietary Information
Process At A Glance Texas Center for Applied Technology
•A Lean Tool that shows elements of a process quickly. •Task oriented. •Helps to create Standard Work. •Very useful for Work Cell design.
28 - TEES/CCAD Proprietary Information
Process At A Glance Texas Center for Applied Technology
Process At A Glance breaks down operations to steps: •Parts •Steps •Tools •Gauges •Machines •Instructions •Time
29 - TEES/CCAD Proprietary Information
Kitting Texas Center for Applied Technology
• Delivery • Located @ point-of-use (POU) • Issued to mechanic • Returned empty for refill
• Contents • Everything required for Job • In the quantities needed
30 - TEES/CCAD Proprietary Information
Kitting (Con’t) Texas Center for Applied Technology
• Presentation • In the sequence used • Cart, container, bins, etc.
• Kit design: • Perform work right to left • Visually signal job status • Color code all labels • Mistake proofing
31 - TEES/CCAD Proprietary Information
Identify Parts Needed Texas Center for Applied Technology
32 - TEES/CCAD Proprietary Information
Shadow Parts Texas Center for Applied Technology
Left: Finished Parts Presentation
33 - TEES/CCAD Proprietary Information
Identify Tool Requirements Texas Center for Applied Technology
Tools for task being laid out for shadowing 34 - TEES/CCAD Proprietary Information
Shadow Tools Texas Center for Applied Technology
Working Smarter not Harder
35 - TEES/CCAD Proprietary Information
Identify New Layout Texas Center for Applied Technology
Staging for Assy
E&E and Prep Workstation
Assy Workstation with Special Tools
Assy Tools
E&E Tools
36 - TEES/CCAD Proprietary Information
Document Standard Work Texas Center for Applied Technology
• Key to productivity of the whole value stream. • Standard Process for performing work tasks hour by hour, day to day, week to week. • Process At A Glance allows simple documenting of standard work methods. • Can be used by operators for training or guidance. 37 - TEES/CCAD Proprietary Information
Kaizen Events in action Texas Center for Applied Technology
38 - TEES/CCAD Proprietary Information
Continuous Improvement Texas Center for Applied Technology
•Know where value is created (or lost) •Start with the end in mind •Identify the high leverage opportunities •Use the lean tools •Stay on course…lean takes time •When you think you are done…time to start again!
39 - TEES/CCAD Proprietary Information
Conclusion Texas Center for Applied Technology
• Work Measurement Standards historic or new help set up Process At A Glance events quickly. • Process At A Glance allows processes with a lot of variability to be standardized.
40 - TEES/CCAD Proprietary Information
Conclusion Con’t Texas Center for Applied Technology
• Process At A Glance allows quick sustainable gains in productivity. • Process At A Glance sets up future events to level load and create assembly lines.
41 - TEES/CCAD Proprietary Information
Texas Center for Applied Technology
42 - TEES/CCAD Proprietary Information
Work Measurement and Process at a Glance in Lean (A case study at the Corpus Christi Army Depot by Texas A&M Engineering) Harry S. Whiting II, MSIE Fred Canales, BSIE Dr. J. J. Congleton, PhD, CPE, PE
1 - TEES/CCAD Proprietary Information
Lean Process Texas Center for Applied Technology
• Preparation for Lean Event • Value Stream Analysis • Prep work for process analysis
• Lean Event • Verify correct process • Eliminate NVA steps
• Future State • Process At A Glance • Run the new process to verify • Implement 2 - TEES/CCAD Proprietary Information
Lean Process (Preparation) Texas Center for Applied Technology
• Value Stream Analysis • Value Stream Map w/ areas of opportunity • TAKT Time calculations
• Prep work for process analysis • Observe and record process • Create Process Map • Layout & Spaghetti Chart • Sort data (VA, NVA, NVAN, Wastes) 3 - TEES/CCAD Proprietary Information
TAKT Time Texas Center for Applied Technology
• TAKT is a German word meaning Beat • Producing to the pace of customer demand (no faster, no slower). • TAKT time = Available time/Customer Demand
4 - TEES/CCAD Proprietary Information
Calculating TAKT Time Texas Center for Applied Technology
Typical TAKT Time Calculation: 991 units = 82.5 units per month 12 months 82.5 = 4.12 units per day = 4 units per day 20 days/month 15 Hrs (2 Shifts) = 3.63 TAKT Time 4.12 5 - TEES/CCAD Proprietary Information
Identify Problem Areas Texas Center for Applied Technology
Observation Time vs. TAKT Time 8
7.32
7 6
5.41
5 4 TAKT 3.63
3 2 1 0 OBSERV. # 1
OBSERV. # 2
6 - TEES/CCAD Proprietary Information
Observe process Texas Center for Applied Technology
Time observations on the shop floor 7 - TEES/CCAD Proprietary Information
Time Observation Texas Center for Applied Technology
• Best way to see waste. • Real facts and data about the operation. • Non-Value added waste is seen in detail.
8 - TEES/CCAD Proprietary Information
Std Work Combination Sheet Texas Center for Applied Technology
New / Revison
________
Organization
Page Work Center
_______
of
Supervisor Time
Step #
Secs.
Process Description
* Start time/date (see notes)
2 Hours
Min.
Value Added manual
auto
_______
Product Line
Standard Work Combination Sheet Part Number
Customer Demand units Available Time
Days
Non-Value Added manual
Date _____________
Operator
travel
queue
Part Name
units
Takt Time
mins.
mins.
sub-total for ref. Start VANVA 0 20 time 40
1
0
0
2
0
0.0
3
0
0.0
4
0
0.0
5
0
0.0
6
0
0.0
7
0
0.0
8
0
0.0
9
0
0.0
10
0
0.0
11
0
0.0
12
0
0.0
13
0
0.0
14
0
0.0
15
0
0.0
16
0
0.0
17
0
0.0
18
0
0.0
19
0
0.0
20
0
0.0
60
80
100
120
140
160
180
200
Notes: Password: stdwork (1 sheet per person)
TOTALS:
VA
NVA
% VA
0
0
#DIV/0!
Secs. format shall be in "hh:mm:ss" + "a/p". i.e. 6:30:25 p Mins. & Hrs. format shall be in "hh:mm" + "a/p". Days format shall be in base numerical format
9 - TEES/CCAD Proprietary Information
220
Work Measurement Texas Center for Applied Technology
• Work measurement is studying a task and breaking it down into elements for analysis. • Texas A&M Engineering does two types of Work Measurements at CCAD • Time Standards: Full breakdown of all work elements • Personal, fatigue and unavoidable delays (PF&D) • Pace rating • Time Observations: Concentrate on waste elements in study 10 - TEES/CCAD Proprietary Information
Time Standard Sheet-Summary Texas Center for Applied Technology
STD. DATA ANALYSIS/APPLICATION OPERATION: PTO (Observation #2) SUPERVISOR: MECHANIC(S): ANALYST(S): # PROCESS SUMMARY A Preperation B Clean PTO gearshaft in varisole booth C Install damper ring onto PTO gearshaft D Apply label to bearing E Sandblast part number onto PTO gearshaft F Install bearing onto PTO gearshaft G Perform backlash test on PTO gearshaft
11 - TEES/CCAD Proprietary Information
IN
OUT 630 160 122 122 662 222 180
DATE: SHOP: OP-CODE: EIC/WPC: NORMAL TIME (min) 23.90 7.68 7.57 19.45 16.03 12.90 24.90
Observation Work Sheet-Detail Texas Center for Applied Technology
STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: Output Shaft SUPERVISOR: MECHANIC(S): DISTANCE ANALYST(S): # Job Description IN OUT A Preperation 1 Go to inventory bins to get parts 50 2 Gathering all parts needed 3 Go to workbench 50 4 Take parts out of bin 5 Verify numbers match for housing 6 Verify numbers match for rotating seal and output shaft 7 Verify numbers match for bearing (1 of 2) 8 Verify numbers match for bearing (2of 2) 9 Go to QC table 20 10 Sell bearings 11 Go to workstation 20 12 Open package of common hardware 13 Clean common hardware 14 File down transfer tube 15 Inspect bearings (inspector) 16 Consult with inspector 17 Put away paperwork Subtotal 140 B 1 2 3 4 5 6 7 8 9 10
Prepare bearings for oven Open O-ring package Install O-rings onto transfer tube and jets Oil up 2 jets and install in housing Go to parts bin (get piston rings) Get piston rings Go to workbench Install piston rings on housing Measure bearings (micrometer) Place hardware onto bearings (to put in oven) Measure rotating seal (micrometer)
46
CATEGORIES DATE: O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: T: Transport/GatheR: Rework PR:Operation NVEIC/WPC: Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. Pr Eng. 0 0 1 1 2 5 8 14 16 16 17 17 18 21 22 23 24
0 27 28 43 10 50 24 45 28 35 25 33 30 7 30 30 20
0 1 1 2 5 8 14 16 16 17 17 18 21 22 23 24 25
27 28 43 10 50 24 45 28 35 25 33 30 7 30 30 20 21
T PR T PR I I I I T I T PR CNVA O I I PR
0.45 1.02 0.25 0.45 3.67 2.57 6.35 1.72 0.12 0.83 0.13 0.95 2.62 1.38 1.00 0.83 1.02
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0.45 1.02 0.25 0.45 3.67 2.57 6.35 1.72 0.12 0.83 0.13 0.95 2.62 1.38 1.00 0.83 1.02 25.35
25 26 27 29 29 30 30 31 32 33
21 43 42 40 55 3 17 23 57 22
26 27 29 29 30 30 31 32 33 34
43 42 40 55 3 17 23 57 22 24
PR O O T T T O I O I
1.37 0.98 1.97 0.25 0.13 0.23 1.10 1.57 0.42 1.03
1 1 1 1 1 1 1 1 1 1
1.37 0.98 1.97 0.25 0.13 0.23 1.10 1.57 0.42 1.03
12 - TEES/CCAD Proprietary Information
Identify Flow Texas Center for Applied Technology
Induct Part
STORAGE GOOD
Evaluation
MACHINE SHOP
NDT Shop
CLEANING SHOP
Component Assembly
WELDING SHOP
BAD
MACHINE SHOP
PLATING SHOP
METAL SPRAY
MACHINE SHOP
NDT Shop
CLEANING SHOP
Typical Part Flow 13 - TEES/CCAD Proprietary Information
HEAT TREAT
Component Assembly
Finished Product
Spaghetti Diagram Texas Center for Applied Technology
• Purpose: To help see movement of people. • Helps to identify waste of motion and transportation. • You can stand back and see the flow, see the waste.
14 - TEES/CCAD Proprietary Information
Spaghetti Diagram Texas Center for Applied Technology
BEFORE RIE Total Distance 2376 ft. (0.45 miles) AFTER RIE Total Distance 1256 ft. (0.23 miles) Savings of 1120 ft.
15 - TEES/CCAD Proprietary Information
Value-Added Activities Texas Center for Applied Technology
1. Is the customer willing to pay for this activity? 2. It must be done right the first time, every time. 3. The action must somehow change the fit, form, or function of the material being worked.
16 - TEES/CCAD Proprietary Information
Non-Value Added Texas Center for Applied Technology
Activities that take time, material, or space but do not physically change the material. 1. 2. 3. 4. 5. 6. 7.
Defects Overproduction Transportation Waiting Excess Inventory Excessive Motion Non Value-Added Processing 17 - TEES/CCAD Proprietary Information
Lean Analysis Sheet Texas Center for Applied Technology
STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: PTO (Observation #1) SUPERVISOR: MECHANIC(S): DISTANCE ANALYST(S): Job Description IN OUT # 3 Wash PTO gearshaft in booth
DATE: CATEGORIES O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: PR:Operation NVEIC/WPC: T: Transport/GatheR: Rework Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. 13 57 16 22 CVA 2.42 1
3 5 7 6 5 5
Inspect PTO gearshaft (make sure serial # matches) File down gear (double check if gear is good/bad) Inspect PTO gearshaft (good/bad) Inspect serial numbers match (double-checking) Inspect bearing and serial #'s match Sell to inspector
4 7 10 17 43 64
0 0 30 30 43 20
6 7 12 18 44 65
0 44 52 12 12 15
I I I I I I
2.00 0.73 2.37 0.70 0.48 0.92
1 1 1 1 1 1
7 2 7 9 1 2 3
Sandblast stencil onto PTO gearshaft Install damper ring onto PTO gearshaft Install bearing onto PTO gearshaft using press machine Torque bearing onto PTO gearshaft Perform 1st run (backlash test)/ record results Perform 2nd run (backlash test) / record results Perform 3rd run (backlash test) / record results
32 38 44 47 50 53 54
43 30 55 44 8 37 37
33 41 46 50 53 54 56
49 15 25 8 37 37 43
O O O O O O O
1.10 2.75 1.50 2.40 3.48 1.00 2.10
1 1 1 1 1 1 1
7 Paperwork (fill out A&I sheets) 4 Paperwork (stamp A&I sheets)
18 56
12 43
21 64
27 20
P P
3.25 7.62
1 1
1 5 3 4 6 1 3 4
12 16 41 41 44 21 25 27
52 50 15 52 12 27 16 25
13 17 41 43 44 23 27 32
30 30 52 43 55 37 25 3
PR PR PR PR PR PR (SB) PR (SB) PR (SB)
0.63 0.67 0.62 1.85 0.72 2.17 2.15 4.63
1 1 1 1 1 1 1 1
Prepare to wash PTO gearshaft in varisole booth Dry PTO gearshaft Grease up PTO gearshaft Open package for bearing/put on latex gloves Put away paperwork Prepare PTO gearshaft for sandblast (apply tape ) Make stencil for part # and serial # Cut/Tape stencil onto PTO gearshaft
18 - TEES/CCAD Proprietary Information
Categorize/Lean Analysis Texas Center for Applied Technology
PTO Lean Analysis (Obs#1) 16.00
14.33
14.00 11.43
12.00
10.87 10.05
10.00 Tim e (m in)
7.20
8.00 6.00 4.00
4.48
3.50
2.42
2.00 0.00 CV A
In sp ec tio n
Op er ati on
Pa pe rw or k
Tr Pr Tr Pr an ep an ep sp er sp er at at o or r ta ion ion tat t i io on (S n an (S d an Bl d as Bl tin as g) tin g)
Category 19 - TEES/CCAD Proprietary Information
Identify NVA and VA steps Texas Center for Applied Technology
(NVA & VA categories) STANDARD DATA ANALYSIS ELEMENT BREAKDOWN/LEAN ANALYSIS OPERATION: PTO (Observation #1) SUPERVISOR: MECHANIC(S): ANALYST(S): # Job Description 3 Wash PTO gearshaft in booth 5 File down gear (double check if gear is good/bad) 1 Get paperwork/A&I sheets 2 Go to inventory bin (get PTO gearshaft) 7 Paperwork (fill out A&I sheets) 4 Paperwork (stamp A&I sheets) 5 Dry PTO gearshaft 3 Make stencil for part # and serial # 4 Cut/Tape stencil onto PTO gearshaft 6 Go to inventory bin (get another PTO gearshaft, got a bad one) 2 Go to varisole booth 4 Go to workstation 2 Go to stencil machine 5 Go to sandblast machine 8 Go to workstation 1 Go to inventory bin (get bearing) 8 Go to borrow run-on (used to torque bearing) 4 Get file brush (toolbox) 3 7 6 5 7 1 5 1 6 9 3 4 6
Inspect PTO gearshaft (make sure serial # matches) Inspect PTO gearshaft (good/bad) Inspect serial numbers match (double-checking) Inspect bearing and serial #'s match Sandblast stencil onto PTO gearshaft Prepare to wash PTO gearshaft in varisole booth Sell to inspector Prepare PTO gearshaft for sandblast (apply tape ) Prepare machine for sandblasting Take tape off PTO gearshaft Grease up PTO gearshaft Open package for bearing/put on latex gloves Put away paperwork
IN
DISTANCE OUT
264 122
122 80 80 316 26 320 122 222
CATEGORIES DATE: O: Operation I: Inspection CNVA SHOP: S: Searching P: Paperwork CVA OP-CODE: PR:Operation NVEIC/WPC: T: Transport/GatheR: Rework Minutes Seconds Minutes Seconds CATEGORY Obs.T. Frq. 13 57 16 22 NVA 2.42 1 7 0 7 44 NVA 0.73 1 0 0 2 20 NVA 2.33 1 2 20 4 0 NVA 1.67 1 18 12 21 27 NVA 3.25 1 56 43 64 20 NVA 7.62 1 16 50 17 30 NVA 0.67 1 25 16 27 25 NVA 2.15 1 27 25 32 3 NVA 4.63 1 8 42 10 30 NVA 1.80 1 13 30 13 57 NVA 0.45 1 16 22 16 50 NVA 0.47 1 23 37 25 16 NVA 1.65 1 32 3 32 15 NVA 0.20 1 33 49 35 28 NVA 1.65 1 37 29 38 30 NVA 1.02 1 46 25 47 44 NVA 1.32 1 6 0 7 0 NVA 1.00 1 4 10 17 43 32 12 64 21 32 35 41 41 44
20 - TEES/CCAD Proprietary Information
0 30 30 43 43 52 20 27 15 28 15 52 12
6 12 18 44 33 13 65 23 32 37 41 43 44
0 52 12 12 49 30 15 37 43 29 52 43 55
NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN NVAN
2.00 2.37 0.70 0.48 1.10 0.63 0.92 2.17 0.47 2.02 0.62 1.85 0.72
1 1 1 1 1 1 1 1 1 1 1 1 1
Identify NVA and VA steps Texas Center for Applied Technology
PTO Observation #1
64.28 70.0
60.0
50.0 35.02 40.0
Time (min)
54.47% 30.0 16.03 13.23
20.0 24.94%
20.59% 10.0
0.0 NVA
NVAN
VA
Type of Steps
21 - TEES/CCAD Proprietary Information
TOTAL TIME (MIN)
Pie Chart Texas Center for Applied Technology
Cabinet for Caps 7.7%
Chemicals 2.5%
Hardware 1.8%
Parts Pallet 6.4%
Work Station 39.6%
PSA Table 14.5% Special Tools 6.1% Aircraft 21.5%
22 - TEES/CCAD Proprietary Information
Fishbone Diagram Texas Center for Applied Technology
Pave Hawk Disassembly Fishbone Diagram 3.14 Hours
10.05 Hours
3.45 Hours
PAPERWORK 5.5%
SET UP 17.7%
CLEAN 6.1% Aircraft 40.1%
44.9% Burr Tags
Aircraft 77.1% 1.3% Workstation
26.9% Part
FOD 15.8%
Hardware 8.7%
Workbook 53.6%
0.6% Personal
10.7% Workstation
1.4% Computer
Tools 5.1% Safety Guards 9.5% 4.1% Tools
1.8% Searching
21.5% Aircraft
82.5% Confer & Assist 7.7% Cabinet
2.8% PC Board
WASTE
Chemicals 2.5%
Parts 6.4%
Part 15.6% 0.7% Tool
6.1% Special Tools PSA Table 14.5%
0.5% PSA
Hardware 25.0%
1.8% Hardware Workbook 0.1%
Workstation 39.6%
OTHER 4.6 %
TRAVEL 27.2%
INSPECTION 22.5%
2.62 Hours
15.40 Hours
12.78 Hours
23 - TEES/CCAD Proprietary Information
56.71 Hours
Lean Process (Event) Texas Center for Applied Technology
• Verify Correct Process • Observed work standard • Flow chart or Process Map • Spaghetti Chart
• Analyze and develop ways to eliminate NVA steps for operator or transfer to assistant
24 - TEES/CCAD Proprietary Information
Verify Process Map Texas Center for Applied Technology
25 - TEES/CCAD Proprietary Information
Value Added & Necessary Steps Texas Center for Applied Technology
VA mapping Chart
4.000
3.63
3.500
3.000
2.500
Tim e (hrs) 2.000
1.500
1.000
0.83
0.75
0.500
0.12 0.080.050.17
0.25
0.17 0.12 0.05 0.03 0.08 0.05 0.07 0.020.020.02 0.020.02
0.33
0.25 0.08
21
22
0.07
0.000 1
2
3
4
5
6
7
8
9
10
11
12
13
14
Process Steps
26 - TEES/CCAD Proprietary Information
15
16
17
18
19
20
23
24
Lean Process (Future State) Texas Center for Applied Technology
• Process At A Glance adds visual data to create Future State for operator • Pictures of Parts, Tools, Machines • Kitting • Tool lists • Parts lists • Hardware lists
• Standard Work Instructions
• Run the new process to verify • Implement 27 - TEES/CCAD Proprietary Information
Process At A Glance Texas Center for Applied Technology
•A Lean Tool that shows elements of a process quickly. •Task oriented. •Helps to create Standard Work. •Very useful for Work Cell design.
28 - TEES/CCAD Proprietary Information
Process At A Glance Texas Center for Applied Technology
Process At A Glance breaks down operations to steps: •Parts •Steps •Tools •Gauges •Machines •Instructions •Time
29 - TEES/CCAD Proprietary Information
Kitting Texas Center for Applied Technology
• Delivery • Located @ point-of-use (POU) • Issued to mechanic • Returned empty for refill
• Contents • Everything required for Job • In the quantities needed
30 - TEES/CCAD Proprietary Information
Kitting (Con’t) Texas Center for Applied Technology
• Presentation • In the sequence used • Cart, container, bins, etc.
• Kit design: • Perform work right to left • Visually signal job status • Color code all labels • Mistake proofing
31 - TEES/CCAD Proprietary Information
Identify Parts Needed Texas Center for Applied Technology
32 - TEES/CCAD Proprietary Information
Shadow Parts Texas Center for Applied Technology
Left: Finished Parts Presentation
33 - TEES/CCAD Proprietary Information
Identify Tool Requirements Texas Center for Applied Technology
Tools for task being laid out for shadowing 34 - TEES/CCAD Proprietary Information
Shadow Tools Texas Center for Applied Technology
Working Smarter not Harder
35 - TEES/CCAD Proprietary Information
Identify New Layout Texas Center for Applied Technology
Staging for Assy
E&E and Prep Workstation
Assy Workstation with Special Tools
Assy Tools
E&E Tools
36 - TEES/CCAD Proprietary Information
Document Standard Work Texas Center for Applied Technology
• Key to productivity of the whole value stream. • Standard Process for performing work tasks hour by hour, day to day, week to week. • Process At A Glance allows simple documenting of standard work methods. • Can be used by operators for training or guidance. 37 - TEES/CCAD Proprietary Information
Kaizen Events in action Texas Center for Applied Technology
38 - TEES/CCAD Proprietary Information
Continuous Improvement Texas Center for Applied Technology
•Know where value is created (or lost) •Start with the end in mind •Identify the high leverage opportunities •Use the lean tools •Stay on course…lean takes time •When you think you are done…time to start again!
39 - TEES/CCAD Proprietary Information
Conclusion Texas Center for Applied Technology
• Work Measurement Standards historic or new help set up Process At A Glance events quickly. • Process At A Glance allows processes with a lot of variability to be standardized.
40 - TEES/CCAD Proprietary Information
Conclusion Con’t Texas Center for Applied Technology
• Process At A Glance allows quick sustainable gains in productivity. • Process At A Glance sets up future events to level load and create assembly lines.
41 - TEES/CCAD Proprietary Information
Texas Center for Applied Technology
42 - TEES/CCAD Proprietary Information
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