1 / 6

Impact Report

1.5” x 12.5” Lower Corner Gaskets. 21100125 / 21100126 – Obsolete Corner Gasket. 3” x 12.5” Corner Lap Gasket. Impact Report. Project: Alpha Lap Plate / Corner Post Gasket Fabrication and Use.

walda
Download Presentation

Impact Report

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 1.5” x 12.5” Lower Corner Gaskets 21100125 / 21100126 – Obsolete Corner Gasket. 3” x 12.5” Corner Lap Gasket Impact Report Project: Alpha Lap Plate / Corner Post Gasket Fabrication and Use. Problem Description:Corner lap plate and lower corner post gasket inventory has been insufficient to support production demands After Before Solution:Utilize obsolete Container Line gasket inventory to fabricate additional gaskets. Benefits:Cost reduction of $15,046 through use of Container Line gasket inventory. Sustainability:GPC and TOI implemented to fabricate and use obsolete inventory.

  2. Impact Report Project: Coupler Lines 1, 2 & 4 – Apron Floor Plate to Wrapper Strip Welding. Problem Description: The Floor Plate to Wrapper joint was welded full length, solid weld. Excessive, unnecessary weld length along with excessive heat input contributing to “Apron Lean” from weld draw. Before After Front Apron Floor Plate Welded Full Length, Solid Weld Front Apron Floor Plate Strip Welded and Caulked Solution: Changed from a full length, solid weld to a strip weld with 3 inch welds on 6” centers.Also added caulking in between the strip welds for water seal. Template provided for proper weld layout. Benefits: $52,143.52 annualized savings {cost of caulk / labor factored in}. Improve product quality. Sustainability: Product / Process design change. Process Audits.

  3. Impact Report • Project: Duraplate – Blender Upgrade (small profile line) • Problem Description: The profile line was sharing a blender with the test line. We had to either shut down profile production to test new materials &/or shut down testing. Also, area was disorganized and held large material inventories tying up cash. • Solution: Installed new blender allowing us to utilize lean strategies. • Benefits: Better utilization of extrusion equipment & lower inventories. • Sustainability: GPC - General Process Change. 3000 lbs of material inventories. 400 lbs of material inventories.

  4. Impact Report Project: Line 5 weld removal. Problem Description: Product Engineering redesigned product line and removed welds. Production was not informed of change and continued to add shim and welds to product. After Before Welds Shims and welds removed Shims added to fill gaps Solution: Informed production that welds were not needed. Benefits: $5,623 annualized savings, Improve product quality. Sustainability: Update Work Instructions, Process Audits.

  5. Impact Report Project: Correct gas flow on six welding machines in North Plant Coupler and Rear Frame Areas. Problem Description:Found missing Gas Flow Restrictors causing excessive shielding gas consumption. After Before Correct Fittings at Manifold Incorrect Restrictor location Correct Restrictor Location At Rear Of Wire Feeder Restrictors Drilled Out Solution: Installed Gas Flow Restrictors. Benefits:$27,162.50 annualized savings. Improve product quality. Sustainability:Process Audits/ Maintenance training.

  6. Impact Report Project: Line 8 floor to side scuff seam weld improvement. Problem Description: If scuff was not completely engaged in floor groove before tack welding, gaps would form and create voids not easily welded with side seam welder, creating rework. After Before No tack welds Tack welds Solution: Discontinue tack welding . Benefits: $10,783.70 annualized savings, Improve product quality and cycle time. Sustainability: Process audit/work instruction.

More Related