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A MACHINING SUCCESS STORY



One of the reasons that we teach all employees the concept of Theory of Constraints is because of the success rate it has of solving problems. A recent use of the concept in the Machining Department is another example of the way it works for us.

IDENTIFY
Problem: Production on the CNC Lathes was not at optimum cycles per shift and needed to be increased approximately 14%.

EXPLOIT
Causes: Some of the causes were identified as gauging and inspection time, material handling, machine cycle time, running scrap parts, maintaining the machine, etc.
Investigate possible Cures: reorganize the work station, review the program, keep staging area full, making the maintenance faster, improve gauging time, etc.

Actions Required: Chart performance of the CNC lathes, add wheels to the chip barrel, employee assigned to clean the machine each week, 5S the area, etc.

Improvement: The CNC lathes are now producing 18.5%! more cycles per shift.

Below - Detailed CNC Improvement Team meeting notes



MEETING 1
CNC Lathe Improvement Team
October 17, 2001 Meeting

Present: Scott Daniel, Terry Pile, John Howze, Kent Frame, Noel Lasher and Debbie Roach
Cc: Dusty Johnson

Identify the Problem:
Continuously Improve Throughput on the CNC Lathes
Let’s cut out the waste (muda) - Currently at XXX cycles /shift (benchmark)

Identify the Possible Causes:
  • Machine cycle time — machine run time (currently XX seconds)
  • Gauging and Inspection time
  • Material Handling
  • Staging
  • Load and Unload
  • Looking for product
  • Getting boxes and pallets
  • Cell Logistics - How everything is arranged
  • Adding Coolant, Water, and Oil
  • Machine Cleaning and Machine Area
  • Running Scrap Parts (i.e. Porosity, Non-fill, or Hard Spots)
  • Operator issues


Investigate the Possible Cures:
  • DEBBIE - Make list of all tools required/how to make then permanently available
  • KENT - Machine cycle time — Review program, set-up and tool changes
  • NOEL - Gauging and Inspection time - Investigate ways to improve gauging time
  • JOHN - Material Handling - Investigate ways to keep staging areas full
  • TERRY - Cell Logistics - Review how everything is arranged and 5S
  • DEBBIE - Adding Coolant, Water, and Oil - Investigate ways to improve
  • KENT - Machine Cleaning - Review schedule and improvements to reduce time
  • TERRY - Scrap Parts - Review the Feedback Loop from machining to die cast

Actions Required:
Kent to call the next meeting for the first week in November.
Terry to type up minutes




MEETING 2
CNC Lathe Improvement Team
November 2,2001 Meeting


Present: Scott Daniel, Terry Pile, John Howze, Kent Frame, Noel Lasher and Debbie Roach
Cc: Dusty Johnson

Identify the Problem:
Continuously Improve Throughput on the CNC Lathes
Let’s cut out the waste (muda) - Currently at XXX cycles /shift

Reviewed Action Items and identified New Actions:
  • Kent & Terry — Locate Cleaning and “shift change” in permanent location per layout and 5S all the items
  • Debbie & Noel — Locate ALL tools, gauges, clipboards, and misc. items required while running on the worktable and 5S all items.
  • Kent & Noel - Investigate and modify LIGHTING required at machine & workstation
  • Kent — Investigate speeds/feeds on machine to reduce machine cycle time
  • Kent - Investigate alternate tooling which would reduce machine cycle time
  • Noel - Added wheels to workstation cart to reduce movement required (completed 10/22)
  • John — Move customer parts in CNC Area
  • John - Help with painting and signs to complete 5S of the CNC area. Reviewed coolant procedure and elected not to make any changes at this time other than having coolant prepared at shift change and available in “cleaning area”
  • Noel - Noel was assigned to clean the machine completely every Friday at the end of his shift
  • John — Add wheels to the chip barrel and remove the pallet.
  • Terry & Kent-Make a chart for the porosity checks for the operators
  • Terry & Kent - Make chart showing CNC Lathe Performance
  • ALL Operators to wipe down, sweep, clean-up the area and help prepare required materials (coolant, boxes, labels. etc.) for the next shift prior to leaving for the day
  • ALL Operators will pick-up a trimmed part on their way back from break or lunch and complete a porosity check. The parts are to be marked as to the time they were taken and a chart is to be completed showing the parts were accented or rejected.

Other Actions:

Kent to call the next meeting in November
Terry to type up minutes



MEETING 3
CNC Lathe Improvement Team
November 27, 2001 Meeting

Present: Scott Daniel, Terry Pile, John H.wze, Kent Frame, Noel Lasher and Debbie Roach
Cc: Dusty Johnson

Identify the Problem:
Continuously Improve Throughput on the CNC Lathes
Let’s cut out the waste (muda) - Currently at XXX cycles /shift

Reviewed Completed Action Items:
  • Kent & Terry - Located Cleaning and “shift change” in permanent location per layout
  • Debbie & Noel - Locate ALL tools, gauges, clipboards, and misc. items required
  • Kent — Investigate speeds/feeds on machine to reduce machine cycle time (At optimum per Vernon Brown —Industrial Supply (Sandvik Rep)
  • John — Move parts out of CNC Area
  • John - Help with painting and signs to complete 5S of the CNC area.
  • Noel — Noel assigned to clean the machine completely every Friday at the end of his shift
  • John - Add wheels to the chip barrel and remove the pallet.
  • Terry & Kent - Make a chart for the porosity checks for the operators and review with team
  • Terry & Kent - Make chart showing CNC Lathe Performance and review with team

New Actions Items:
  • Kent & Noel - Investigate and modify LIGHTING required at machine & workstation
  • Kent — Move coolant and way lube oil under end of machine and label
  • Kent — Make a place for the box dividers on the back of the workstation
  • Terry & Kent — Identify Scrap Baskets and a Place for Clean-up Rags
  • Terry — Change charts per discussion and issue for use ASAP.
  • Terry - Make labels for tools on pegboard, Coolant and Way Lube oil
  • Terry — Chart performance data from January of 2001 to date for benchmark.
  • John & Kent — Meet to review WIP in CNC area and training of employees
  • Kent — Work with employees to help them identify personal improvements to meet rate
  • Terry - Type up minutes

Next meeting to be scheduled after completion of TYD Performance Chart by Terry.

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