Drill Press 09 Setup Reduction Kaizen Blitz September 9 - 13, 2002

1. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Drill Press 09 Setup Reduction Kaizen Blitz September 9 - 13, 2002 Casey

2. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Objectives: • Reduce setup time by 50% • Establish Standardized Work for Setup • 5S the Work Cell Casey

3. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Roger Micks • Len Burgess • Shawn Knox • Jaime Cintron • Casey Bralla • Kaizen Team: • Robert Keith • Wavell Burns • Richard Stevens • Peter DiCamillo • Stanley Rate Roger

4. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Thanks to Bedford for allowing participation by their best looking, smartest, hardest working personnel. • Lots of good cross-pollination ideas • Helps establish “best practices” in both Bedford and Collingwood. Roger

5. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Working Together Roger

6. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Drill 09 Background: • Used for Swing Rails • Worst case setup, due to 24 drill chucks • Lessons learned on this machine can be applied to other drills. • Setup time had been improved last year from 40+ hours to ~ 4 hours. Len

7. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Improvements Made: • Organized & 5S’d three setup carts to ensure all components are available before setup begins. • Changed procedures to ensure only good machine components are presented for setting up the machine. • Improved setup sheets to list number of chucks needed to help the Stores Attendant in getting materials ready. • Created Shadow Boards to 5S and standardize tooling locations. • Reduced the number of different types of fasteners (only 1 wrench needed) • Improved chuck mounting method to speed setting in place. • 5S’d the area: Painted lines, Sorted unneeded equipment, labeled locations and equipment. • Revised the setup SOP. Len

8. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Productivity Improvements: Organized and 5S’d three setup carts. All needed components are present. Wavel

9. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Productivity Improvements: Tooling on setup cart sorted to eliminate hunting for correct tools. Wavel

10. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Productivity Improvements: Redesigned mounting method for chucks. Improve ergonomics and speed setup. Jaime

11. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Productivity Improvements: Ergonomic strain. Had to hold chuck in place while tightening bolt. Stanley

12. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Productivity Improvements: Redesigned mount. Do not have to hold chuck in place while tightening. Stanley

13. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Machine Improvements: Low cost chuck supports prevent chuck from moving, & frees-up a spare chuck. Shawn

14. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Standard Procedure Improvements: Red Tag: Chuck needs repair and cannot be used. Richard

15. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Standard Procedure Improvements: Green Tag: Chuck is OK to use. Richard

16. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • 5S’d the work cell: • Lines mark incoming, outgoing product. • Storage shelves for needed tooling organized and labeled. • Safety equipment labeled. • Unneeded equipment removed from the cell. • Shadow boards created for hand tools and cleaning supplies. Robert

17. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S Improvements: Cell layout with lines for incoming and outgoing materials. Robert

18. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S / Safety Improvements: “Third Arm” location established and labeled to ensure they are used efficiently. Robert

19. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S Improvements: All items labeled. Only needed items kept in work cell. Peter

20. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S Improvements: Shadow board for frequently-used tools and gages. Peter

21. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S Improvements: Frequently-used gages labeled. Peter

22. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz 5S Improvements: Added warning signs to machine guard. Peter

23. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Lean Scorecard: Old New Change Setup Time 4.0 hours 1.5 hours 62% Lead Time - - Red 2.5 hrs Inventory - - “Big Problem” Floorspace - - “Controlled” Scrap - - $35/su Pieces per man-hour No Change No Change - Casey

24. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Blitz Savings: Can make more than twice the number of setups in the same amount of time, without cost penalty. This gives us the opportunity to reduce inventories Casey

25. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • 30 minute (or less) setup: • Require equipment and layout changes to get to 30 minute setup. • Need $63K for machine modifications (duplicate tooling for external pre-set) • Need $50K for cranes, which can be common to many machines. Casey

26. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz • Future Plans: • Implement 5S in other drill cells. • Find quick change chucks (no keys needed) • Fabricate toggle clamp for chuck supports. • Design & Build drill preset fixture • Design & Build improved guards to eliminate third arm. Roger

27. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Join us in the Journey! We need your help to carry forward throughout the plant. We need fresh ideas and fresh perspectives. We are all part of the new solution! Roger

28. Backyard Products Drill Press 09 Setup Reduction Kaizen Blitz Thank You! Group