Continuous improvement meeting april 23 24 2007 litchfield mi metaldyne korea
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Continuous Improvement Meeting April 23-24, 2007 – Litchfield, MI Metaldyne Korea PowerPoint PPT Presentation


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POWERTRAIN GROUP. Continuous Improvement Meeting April 23-24, 2007 – Litchfield, MI Metaldyne Korea. Safety Performance. Lean Assessment. [Note: double-click on this chart to open data entry window; enter current and February 2006 summary data from Lean Assessment file]. Define the Problem

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Continuous Improvement Meeting April 23-24, 2007 – Litchfield, MI Metaldyne Korea

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Continuous improvement meeting april 23 24 2007 litchfield mi metaldyne korea

POWERTRAIN GROUP

Continuous Improvement Meeting

April 23-24, 2007 – Litchfield, MI

Metaldyne Korea


Safety performance

Safety Performance


Lean assessment

Lean Assessment

  • [Note: double-click on this chart to open data entry window; enter current and February 2006 summary data from Lean Assessment file]


Lean assessment discussion reduce inventory

Define the Problem

Inventory Turn

Finding Root Cause of Overstock

Team Training/ Seminar, Visual Factory, etc

“Inventory Status” & “Shipping Plan Sheet”

Define

Measurement

Analysis

Improvement

Control

Lean Assessment Discussion-Reduce inventory

1. Define (Problem)

1) MKL had too much stock.

(President’s Request: 25% Reduction)

2) MKL Procurement & Logistics Team lacked of Knowledge/ Skill for Inventory Control.


Lean assessment discussion reduce inventory1

Lean Assessment Discussion-Reduce inventory

2. Measurement

  • Average Inventory Turn of Component : 19.5 turns

  • Average Inventory Turns of All Stock : 9.2 turns

3. Analysis

  • Procurement & Logistics Team are lack of Back Ground Knowledge for Inventory Control.

  • Inventory was controlled by Experience and Vague Forecast, not by Scientific Method (IE Approach).

  • Inventory was controlled by Push System (MRP), not by Pull System (JIT/ Toyota System).

  • Inventory was not controlled by Priority (ABC/ PQ Analysis Data).

  • Proper Visual Factory for Inventory Control was not in place.


Lean assessment discussion reduce inventory2

A Group

B Group

C Group

Lean Assessment Discussion-Reduce inventory

4. Improvement

1) Team achieved Scientific Management Skill

through Education/ Training and Team Seminar.

-. ABC (or PQ) Analysis

-. Ordering System

Fixed-Period Sys, Fixed-Q’ty Sys, Two-Bin Sys,

Safety Stock, etc.

-. Visual Factory

2) Apply the Knowledge to Reality.

-. ABC Analysis (by Jeremy)

A Group: Components from US Supplier

-. Ordering System

A Group: Fixed-Period, B Group: Fixed-Q’ty, C Group: Two-Bin

-. Visual Factory (by YongBae Lee)


Lean assessment discussion reduce inventory3

Lean Assessment Discussion-Reduce inventory

5. Control-Result

1) Inventory Turn: From 9.2 Turns to 17.9 Turns

(World Class: Over 10 Turns Ex: GM 10 Turns)

Target for 2006 is Over 15 turns. (10 turns Inc. parts on the ship)

2) Reduction Amount

708 MKW with Qt’y of 21,186 BSMs in Jan. 2006

; means 1,001MKW with Qt’y of 30,000 BSMs.

; amount to saving 4,167,000 KW per month (if 5% Bank interest is considered)

AVG. 9.2


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