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Cost Reduction Initiative for Pencil Slat Production Optimization

An overview of Phase II emphasizing goals, methodology, and tool highlights for enhancing production efficiency and reducing costs. Course objectives, project background, implementation strategies, and achievement measures are detailed for management professionals.

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Cost Reduction Initiative for Pencil Slat Production Optimization

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  1. Phase II Short FormPencil Slat Cost Reduction Initiative Industrial Technologists' Toolkit For Technical Management QS 327 Team 2: Scott Sowders, Pam Neill, David Harrison, Vanessa Malone, William Myles, John Wise, Shawn Myers

  2. Phase II Contents: • Project Background • Course Objective • Phase II Overview • Phase II Goals • Phase II Methodology • Phase II Highlights

  3. Project Background • QS 327 Class Requirements • Fulfill assignments assigned in syllabus • Review and apply methodology in Industrial Technologists’ Toolkit for Technical Management (ITTTM) • Utilize team oriented philosophies and communication • Pencil Slat Production • Process improvements need to be identified. • Cost opportunities need to be explored. • Documentation needs to be supplied to demonstrate accuracy and value in our results.

  4. Overall Course Objectives • Identify problems with pencil slat production that pertain to cost. • Identify options to improve processes that yield cost savings. • Complete 6 tool kit assignments (tools 19 – 24). • Complete 2 phase projects. • Streamline RCA and SDA documentation posting cycles. • Attain scores based on benchmark of 30.

  5. Phase II Overview Tool 22 “Synchronous Production: Enhanced Best Practices For Change, Lean, Variation Reduction “ Tool 23 “Failure Mode and Effects Analysis (FMEA), Quality Function Deployment (QFD), Reliability for Robust Problem Solving” Tool 24 “Total Productive Maintenance (TPM), Safety and Ergonomics, Re-engineered Lean Environment”

  6. Phase II Goals

  7. Tool 22 Goals • Identify wasted capacity in wooden slat cutting process. • Analyze internal and external processes and operation levels • Analyze WIP and Takt identifying potential wastes. • Complete current Tool 22 Portfolio • Attain tool score of 30 Points

  8. Tool 23 Goals • Identify options to improve cutting process at a cost reduction • Quality improvement through reduction of failures and identification of causes • Complete Tool 23 Portfolio ahead of schedule • Improve and streamline reporting process in order to obtain score of 30 points

  9. Tool 24 Goals • Identify options to improve cutting process at a cost reduction • Process and quality improvements through preventive maintenance, safety, and ergonomic initiatives • Complete Tool 24 Portfolio ahead of schedule • Improve and streamline reporting process in order to obtain score of 30 points

  10. Phase II Methodology

  11. Tool 22 Methodology • OCA – Operation Capacity Analysis • GBAPS – General Benchmarking/Auditing Process • SOPATA – SOP and Takt Analysis

  12. Tool 23 Methodology • OPCP - On Going Process Control Plan • SOGA - Standard Operation General Analysis • FMEA - Failure Mode and Effects Analysis • QFD - Quality Function Deployment • CEAS - Characteristic Evaluation And Audit System

  13. Tool 24 Methodology • OPCP - On Going Process Control Plan • SOGA - Standard Operation General Analysis • GSICPC - General Safety Inspection Checklist / Perato Chart • MTA - Maintenance Tracking Analysis • GFAPS - General Failsafing / Auditing Process, Systems

  14. Phase II Highlights

  15. Tool #22 Highlights: For competitive production, data, documentation & leadership must be synchronized. Best practices for completion: • Data and documentation (base of all else) • Discipline (details, continuously as the 5 why’s) • People (assure job security, use their ideas) • Technological simplicity & waste reduction • Inventory (reduce to nothing) • Control quality • Change (essential to be competitive)

  16. Tool 23 Highlights • Failure Mode and Effects Analysis (FMEA) • Design for Product and Process • Product Liability and Reliability • Finite Element Analysis (FEA) • Quality Function Deployment (QFD) for lean • General Reliability Issues for Kaizen and FMEA

  17. Tool 24 Highlights • Basic Maintenance Requirements and Lean Service Relationships • Types of Maintenance • Total Productive Maintenance (TPM), Synchronous Quality for Lean • Safety, Human Factors, Quality Objectives • Safety and Ergonomic Management • Controlling Physical Conditions for Ergonomic Enhancement

  18. Conclusion • Pencil slat project is complete. • Team successfully phased the posting cycle into a more, streamlined approach. • Team improved benchmark scores; tools 23 and 24 both received a perfect score of 30pts. • Team process flowed smoothly which has allowed tools and portfolios to be completed prior to required due dates.

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