TPM - OEE Problem: Stillstand der Maschinen für den Bediener nicht sichtbar Aktion: Installation von Signallampen Vorher Nachher Ergebnis: Maschinenstillstand erkennbar, sofortige Reaktion möglich -> längere Laufzeit
Single Page Plan - Management-Tool zur Prozessvisualisierung 1 2 Single Page Plan VSM Kaizen Date: 4/21/03 ->4/24/03 Background • On-time delivery 32% • Yearly scrap cost $747k 3,000,000 2,500,000 2,000,000 1,500,000 1,000,000 500,000 • Quality: green yield at 95.2% • Auto CVD represents 22% of plant Units - KN01 MS01 KN03 KN02 MS02 MS03 CA03 KN04 MS04 CN05 Auto CVD Top 4 represent 85% of volume CA07 CN01 MS12 CA09 Components • Multitude of new high growth products introduced into plant Supplier Raw Purchase Daily Value Stream Mapping – Current State Press 13 Press 6 Press 6 S i n t e r 6 week forecast Daily FAX S e p a r a t e Hone 9 Hone 3 T&B Grind 7 T&B Grind 4 T&B Grind 4 Periphery Grind 34 Sap Daily Production Scheduling Hone 3 PreCoat Vaqua 1 Electro Polish 2 Electro Polish 1 Forecast 90/60/30 Daily Order <strong>Lean</strong>Jet Wash 1 Crest Wash 1 Auto CVD 1 Furnace 14 PreCoat Vaqua 1 Berney Polish 1 CA02 CA04 CA13 CA16 CN04 MS14 MS10 MS05 OEM Mark Pack QC Ship CN03 CA01 CN08 <strong>Kennametal</strong> Distribution Daily Brush Branson T&B Periphery Hone Polish Wash Press Grind Grind 1 2 1 2 Furnace 10 3 34 Separate 1 7.8 days .3 d .4 d 1.5 d .4 d 2.2 d C.T. 420 s 1.1 d 1.9 d .4 d 3.3 d .1 d .6 d CT 10 s CT 61,200 s C.T. 1 s CT 180 s C.T. 120 s C.T. 120 s C.T. 180 s C.T. 960 s CT 1800 s CT 79,400 s C.T. 360 s C.T. 1800 s CT 78 s <strong>Lean</strong>Jet Wash 1 <strong>Lean</strong>Jet Wash 1 SMPL 3 units Lead time 21.9 Days Cycle time 1.9 d Takt Time 3.78 s Supplier Raw Purchase Purchase Daily P l a n Value Value Stream Stream Mapping Mapping Mapping – Future State P r e s s F III F O S i n t e r Implementation Plan •Work details of Future State •Review lead-times & safety stock qty. •Level load high volume items •Establish inventory turns •Setup Reduction for Press operation •Establish FIFO lanes •Error Proof process •TPM process at customer critical points •Standard Work Kaizen on Auto CVD Furnaces and Top Coat Furnace Metrics F III F O H o n e F III F O WIP: Finished Goods : Scrap: Material: Floor Space: Setup Reduction: Cycle Time: Productivity: Administrative: 6 week forecast forecast forecast Daily FAX E P l o e l c i t s r o h F III F O V B a l q a u s a t May 03 Baseline Wash I I F III F F III O F O FIFO FIFO FIFO FIFO FIFO FIFO Ma y June July RESP 2 9 16 23 30 7 1421285 1219 Staff Lgst Lgst Lgst KC8050 KC8050 KC8050 KC9110 KC9110 KC9110 KC9125 KC9125 KC9125 KC9315 KC9315 KC9315 KC9025 KC9025 KC9025 KC9045 KC9045 KC9045 KC9245 KC9245 KC9245 KC9225 KC9225 KC9225 KC9010 KC9010 KC9010 KC990 KC990 KC990 KC9120 KC9120 KC9120 Mfg 1 •Determine placement of FIFO lanes Mfg 1 F III F O F III F O Sap Daily Production Production Production Scheduling Scheduling Scheduling Mfg 1 Mfg 2 Mfg 3 Mfg 3 6 month Projection 140,000 pcs. 92,000 pcs. 4.8% 2.0% NA NA Process Layout Product Layout 1.9 days 1.9 days 24 employees 21 employees FIFO FIFO FIFO Separ ate Ber ney MPL FIFO Forecast 90/60/30 Daily Order �� � Dedicated Dedicated Dedicated equipment equipment equipment by grade Separ Separ Separate ate FIFO FIFO FIFO FIFO OEM Br ush Polish Separate Separate Separate MPL 5 days .3 d .4 d .5 d .4 d 2.2 d 1.1 d 1.9 d .4 d 1.3 d .1 d .6 d CT 10 s CT 61,200 61,200 s C.T. 1 s CT 180 s C.T. 120 ss s C.T. 420 ss s CT 1800 1800 ss s C.T. 960 ss s CT 79,400 79,400 79,400 sss C.T. 360 sss CT 1800 sss C.T. 78 sss Total Savings $40,320 $85,603 -0- TBD 28 min 21 min $35,119 -0- $151,975 NA NA -0- <strong>Kennametal</strong> <strong>Kennametal</strong> <strong>Kennametal</strong> Distribution Distribution Distribution Lead time 16.9 Days Cycle Cycle Cycle time 1.9 d Takt Time 3.78 s 23 3 4 5