Lean bei Kennametal - CETPM

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
LeanJet
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
Kennametal
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
LeanJet
Wash
1
LeanJet
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-
Kennametal Kennametal Kennametal
Distribution Distribution Distribution
Lead time 16.9 Days
Cycle Cycle Cycle time 1.9 d
Takt Time 3.78 s
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