Phase II Short FormPencil Slat Cost Reduction Initiative Industrial Technologists' Toolkit For Technical Management QS 327 Team 2: Scott Sowders, Pam Neill, David Harrison, Vanessa Malone, William Myles, John Wise, Shawn Myers
Phase II Contents: • Project Background • Course Objective • Phase II Overview • Phase II Goals • Phase II Methodology • Phase II Highlights
Project Background • QS 327 Class Requirements • Fulfill assignments assigned in syllabus • Review and apply methodology in Industrial Technologists’ Toolkit for Technical Management (ITTTM) • Utilize team oriented philosophies and communication • Pencil Slat Production • Process improvements need to be identified. • Cost opportunities need to be explored. • Documentation needs to be supplied to demonstrate accuracy and value in our results.
Overall Course Objectives • Identify problems with pencil slat production that pertain to cost. • Identify options to improve processes that yield cost savings. • Complete 6 tool kit assignments (tools 19 – 24). • Complete 2 phase projects. • Streamline RCA and SDA documentation posting cycles. • Attain scores based on benchmark of 30.
Phase II Overview Tool 22 “Synchronous Production: Enhanced Best Practices For Change, Lean, Variation Reduction “ Tool 23 “Failure Mode and Effects Analysis (FMEA), Quality Function Deployment (QFD), Reliability for Robust Problem Solving” Tool 24 “Total Productive Maintenance (TPM), Safety and Ergonomics, Re-engineered Lean Environment”
Tool 22 Goals • Identify wasted capacity in wooden slat cutting process. • Analyze internal and external processes and operation levels • Analyze WIP and Takt identifying potential wastes. • Complete current Tool 22 Portfolio • Attain tool score of 30 Points
Tool 23 Goals • Identify options to improve cutting process at a cost reduction • Quality improvement through reduction of failures and identification of causes • Complete Tool 23 Portfolio ahead of schedule • Improve and streamline reporting process in order to obtain score of 30 points
Tool 24 Goals • Identify options to improve cutting process at a cost reduction • Process and quality improvements through preventive maintenance, safety, and ergonomic initiatives • Complete Tool 24 Portfolio ahead of schedule • Improve and streamline reporting process in order to obtain score of 30 points
Tool 22 Methodology • OCA – Operation Capacity Analysis • GBAPS – General Benchmarking/Auditing Process • SOPATA – SOP and Takt Analysis
Tool 23 Methodology • OPCP - On Going Process Control Plan • SOGA - Standard Operation General Analysis • FMEA - Failure Mode and Effects Analysis • QFD - Quality Function Deployment • CEAS - Characteristic Evaluation And Audit System
Tool 24 Methodology • OPCP - On Going Process Control Plan • SOGA - Standard Operation General Analysis • GSICPC - General Safety Inspection Checklist / Perato Chart • MTA - Maintenance Tracking Analysis • GFAPS - General Failsafing / Auditing Process, Systems
Tool #22 Highlights: For competitive production, data, documentation & leadership must be synchronized. Best practices for completion: • Data and documentation (base of all else) • Discipline (details, continuously as the 5 why’s) • People (assure job security, use their ideas) • Technological simplicity & waste reduction • Inventory (reduce to nothing) • Control quality • Change (essential to be competitive)
Tool 23 Highlights • Failure Mode and Effects Analysis (FMEA) • Design for Product and Process • Product Liability and Reliability • Finite Element Analysis (FEA) • Quality Function Deployment (QFD) for lean • General Reliability Issues for Kaizen and FMEA
Tool 24 Highlights • Basic Maintenance Requirements and Lean Service Relationships • Types of Maintenance • Total Productive Maintenance (TPM), Synchronous Quality for Lean • Safety, Human Factors, Quality Objectives • Safety and Ergonomic Management • Controlling Physical Conditions for Ergonomic Enhancement
Conclusion • Pencil slat project is complete. • Team successfully phased the posting cycle into a more, streamlined approach. • Team improved benchmark scores; tools 23 and 24 both received a perfect score of 30pts. • Team process flowed smoothly which has allowed tools and portfolios to be completed prior to required due dates.