FROM: Scott Daniel
DATE: July 30,01
We have recently been working together attempting to increase our shots per hour in
Die Casting. Following is a major success story from this team effort, written in the
T.O.C. format, so that everyone can see exactly how well it works:
1) Identify the Constraint! By studying data from our "shots per hour" report, we
determined that 3rd shift start-ups on Mondays was always our lowest shift which made
Mondays our lowest day. It's probably no coincidence that Mondays are also our
highest scrap days, for the same reasons.
2) Exploit the Constraint: Some of the causes for start-ups being our lowest shots
per hour are A) Stuck parts B) Operator absenteeism, with no-one to stay over C)
Trim lines full D) Too many machines left down from shut-down. The cures to these
problems are A) Have difficult start-up jobs anti-solder waxed at shut-down and have
only experienced operators start them up on 3rd shift B) Have some second shift
operators call in at start-up to cover for missing 3rd shift operators C) Have the trim
lines cleared prior to shut-down so 3rd shift has room on the lines D) Have a rule at
shut-down which assures a back-up machine at start-up.
3) Subordinate to the Constraint: Just like Herbie in "The Goal", a meeting was
held with Texas Die Casting employees so as to help 3rd shift with their start-up nights.
Action plans have been now developed in each support area to assure that 3rd shift has
extra machines or operators to make start-ups more productive.
4) Elevate the Constraint: During June, before the T.O.C. project started, 3rd shift
had 4056 shots one start-up night. This averages 39 shots per hour. On Monday 7-30-
01, this number leapt to 8002 shots, or 71 shots per hour. This is an 82%
improvement on start-ups.
5) Inertia: Congratulations to 3rd shift on this huge
improvement and thanks to all employees who are
helping Herbie. We can use some of these methods to
improve strikes per hour on every shift, if we work
cc: Dusty Johnson and All Supervisors