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Lean Activities&Overview GE Energy HungaryGE Proprietary and ConfidentialLean Implementation 2004-200720032004200520065S Implementation Point Kaizen Shingi AWO Kitting Employee suggestion system Flow Kaizen First“Model Line”Kanban New employee suggestion system Lean training 25 pers.3“Model Line”Lean metrics Kaizen Commando Work with supplier Lean training 100 pers.Lean Core TeamLeanVision2007 Foundamentally reconsider operational procesessDeveloping long term lean vision/strategy for each cell Implement Lean assembly lines ITO-OTR process mapping Lean CommitteeSuggestion evaluation and award systemBuilding of Lean CultureCurrent focus-Stator-Combustion-Repair-Facility&MaintenanceNew areas Jenbacher,LM6000 Logistic 14 suggestions/week Support functionsFinance,SourcingHR,IT,BD,EHSEmployee Suggestion System extension in 20075S monthly audit and competitionYTD 5S Scoring5S Cap5S Cup handed over by GMCombustion SMED on C&L cone press machineCombustion Fuel Nozzle Assembly lineCombustion TP 7E-9E mixed model lineStator Diaphragm teething machineStator Nozzle stg2&3 Single Piece FlowStator Shroud Lead time and WIP reduction JenbacherDesign container assembly lineLean Activities SMED on C&L cone press machineObservationResult:-The change over took 175 min-Operators took 245m walk-Second operator needed-Safety issuesOut of 175 min 47 was moved to external Separate internal and external timeReduce external timeReduce internal time49 min reduction by implement Hydraulic pump15 min reduction by locating the press tools next to the machine Using 3P to design process to change the tool in 10 minutesFixture changer and storageClamp the press dies by screwMove the press dies like one unit BeforeAfter594New ObservationChanges-Changeover time from 175 min to 594 sec-Walking distance from 245m to 16 m-No forklift or crane required-Safety issues eliminatedSMED videoLocate shadow board to the consoleFuel Nozzle Assembly lineJob-shop workstationsOne operator assembles one endcoverNo flowOriginal Situation 2004Assembly carts storage takes up spaceBoxing storage areaPulse line 2005The Fuel Nozzle operations have been divided into 4 Takt-s.The carts are moving in every 3 hours Pulse line-Single piece flow 2006 Q2Build single carts to implement single piece flowThe Kits Prepared by warehouseFlow testFIFO shelves for subassembliesLoad stationJib craneMoving Line Q3 2006Chain drivenSafety equipmentsShingi AWO July 2006Material presentationStandard WorkTotal Investment NeedsChain91 USDChain-wheels55 USDBearings 182 USDInfra-red pointers54 USDTOTAL 382 USDKAIZEN means significant resultswith“no cost”Built by ourKaizen TeamCombustionModel LineMoving line videoPulse LineMoving Line“Gipsy”productionSingle Piece Flow LT 20 shiftsMan hours 380 minTurn 17.5LT 12 shiftsMan hours 360 minTurn 50.7LT 6 shiftsMan hours 344 minTurn 90LT 4 shiftsMan hours 300 minTurn TBD80%LT reduction within 2 yearsFuel Nozzle Assembly 2004-2006TP 7E-9E mixed model lineProcess at a glanceComparing 9E and 7E processesOld TP7E and 9E routingsNew TP7 and 9 routingStandardize Oracle routingsOperator Need:3 fitter 3 welder 1 NDT 1 FPI 1 Milling 1 QualityStandard combination sheet for all operationShared resourcesDefine standard work for each operators on the line7E-9E mixed line 7E Fixture transferTP7E welding fixture will not be usedTP7E welding fixtureTP9E welding fixtureTP7E checking fixtureTP9 welding fixture will not be usedTP7E Pressing machineImprove material flow-Simplify routing steps-Reduce the number of FPI and sizing operations-Using multi-skilled operators-Using mobile fixturing-FIFO+Single piece flowBeforeAfterKaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsNem tlthat a raktrbl kihozott anyagok mennyisge Az anyagokat kitekben hozza ki a raktrNem kell keresni az anyagokat 10 perc id megtakaritsKaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAnyag trolsA tl sok anyag a terletenKANBAN rendszer bevezetse kis anyagokraKANBAN krtya a testreKevesebb bepl anyag a terletenKaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsKeretoldal kalibralasA klnbz tipusok kszlkei ms helyen vannakA boxok kzs falnak elbontsa.A kszlkek elfrnek az sszenyitott boxban.7E fixture9 Long fixture9 Short fixtureTarget:WIP:35pcs-8pcsLT:10days-4shiftsObservation sheetStd Work CombinationStd Work SheetTP 9E Production FlowParadigm change;from job-shop to mass production-BOM&routing change LPID-Implemented Standard Work Sequence-Visual Management-Redesigned Layout-Material presentation,Kitting,Kanban-Production board-Operator training matrixBenefitLT Reduction by 65%WIP Reduction by 50%(1.2M USD)11%Labor efficiency improvementSmall Parts Kitting Main Parts Kitting Replenishment systemE-Production BoardDiaphragm teething machineOld teething machineStep 1Lift in the 9 E Stg 2 fixture into the machine(10min)Step 2Positioning and Fastening the fixture on the machine(12min)Insert new driver curve(15min)Step 3Step 4Step 5Find the right size gauge for end switch setup(8 min)Setup the end switches on both side two places(15min)1,5 hours changeover timeTeeth Assy machineDS202m VTLDS20 2m VTLBulard2m VTLFAREL2m VTLThunderMillingThunderMillingCincinattiMillingThunderMillingOSP millingMILLNGTURNINGFixture loading for next turning jobDiaphragm process-The diaphragm parts came from 5 different milling centers-The setup time is 1.5 hrsUsing 3P to design new machine9EStg 2 teething6B Stg 2 prepared on the fixture tableChanging the machine teething diameter to a predefined value:one minuteStep 1Step 2Step 3Predefined valuesBefore KaizenAfter Kaizen“U”shapearrangement Teeth KanbanNozzle stg2&3 Single Piece FlowStandard work combination sheet for manual operations Products on the Bay 3 production area:9Est2,9Est3,9FAst2,6Bst2,6Bst3Calculated Takt Time:0.8 hours/segment9E stg2 cyclesCycle time vs.T/TKaizen ideas to design flowBefore KaizenAfter Kaizen OperationNozzle assemblyProblem DiscriptionNO special screwdriver for air-box screw Action TakenSpecial screwdriver made by operatorsResultShorter cycleSafety toolKaizen activityKaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAssemblyNo flowRearrange the layoutParallel flow assembly arialLOCATORBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAssemblyLess waiting timeThe nozzles wait for the last piece to start assembly Small tables implemented to make 3 piece assembly SET BOOKBefore KaizenAfter KaizenOperationProblem Actions TakenResultsSet book for millingNozzle assemblySet book for assemblyProduction boardWeekly assembly planDiaphragm supermarketMaterial presentationAssembly Kitting Seal Kan-BanAccomplishmentsBefore KaizenAfter Kaizen OperationNozzle assemblyProblem DiscriptionThe welding KIT-s are far from the welding boots,too many walking and searching Action TakenMove the locators of welding KIT-s closer Kaizen activityResultNo searching,no messExtend the flow to milling operationMilling 2Milling 4Milling 1Milling 3WasherAssy4Assy3Assy2Assy1CMMCMMWeld1Weld2Weld3Deb 1Deb 2Deb 3Meas1Meas2Meas3Meas4Milling 2Milling 4Milling 1Milling 3WasherAssy2Assy1CMMCMMWeld1Weld2Deb 1Deb 2Meas1Meas2Meas3Meas4OP1OP1OP2OP2BeforeAfterNo dedicated milling centersLong milling cycle timeLot of WIPRed line 6B,9E,9FA second stagesOrange line 6B,9E,9FA third stagesLT reduction 30-40%WIP reduced by 50%6Bstg3 and 9Estg3HN98%machine load6Bstg2 and 9Estg2HN75%machine loadTakt time vs Cycle time ANALISYSMove to OP2Kaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsNew layoutbay3.Too many assembly tableNew layout implementedClear processNozzle stg2&3 Single Piece Flow 2004-2006Single Piece Flow enablers-Product lines-Dedicated resources-Eliminate quality issues-BOM,routing restructuring-Process simplification-Redesigned Layout-Production board-Kan-Ban system-Inspection by operatorsBeforeDiaphragm supermarketMaterial presentationAssembly Kitting Seal Kan-BanAfterBenefitIn house manufacturing lead time6B stg2&3 6 shifts9E stg2&3 9 shiftsShroud Lead time and WIP reductionSourcingOracle MRP(1 day)PSIOracle MDS(1 day)Prodn Cont.Oracle,MPS Level loading(2 days)Customer-1 year forecast(rolling)-PO-s for Quarters-S1 Long term forecast(3 years)-PO 6 month in advanceWeeklyScheduleEvery 6 weeks2 times/weekITurning 1DrillingMillingAssyOrdersOrdersOXOXCurrent State Map Shroud 7FA stg2 SupplierTurning 2SawPackingDeburr.EDMCleanaingHoneycomb brazing farm inBrazing SupplierSparepart Inventory14d5h1h8h30.5h7.5h39h9.5h49h12hlocator to stop overproduction0.5d3.5d3.6d0.5d2d0.5d0.5dBatch size reductionI162 hrs JOB in 28 days50%of the total LT is OSP1d3d1dAfterBefore KaizenAfter KaizenImplement production board and locators for each milling machineSourcingOracle MRP(1 day)PSIOracle MDS(1 day)Prodn Cont.Oracle,MPS Level loading(2 days)Customer-1 year forecast(rolling)-PO-s for Quarters-S1 Long term forecast(3 years)-PO 6 month in advanceWeeklyScheduleEvery 2 weeks2 times/weekITurning 1DrillingMillingAssyOrdersOrdersOXOXCurrent State Map Shroud 7FA stg2SupplierTurning 2SawPackingDeburr.EDMCleanaingSparepart Inventory2d5h1h8h30.5h7.5h39h9.5h49h12h0.5d2d2d0.5d0.5d0.5dI162 hrs JOB in 15 days13 days reduction46%reduction1d3d1dBrazingwelding8h8h1dAfterBatch size reductionDesign container assembly lineTakt Time and assembly stations-Yearly demand 170-180-Available Working time 50w x 5d x 7hrs=1750 hrsTakt time=1750 hrs180=10 hrs-Total assembly time 320 hrs before test(without preparations)-3,5 operators can work at the same time on one unit420 JGC 3mAssembly stations=320 hrs/3.5T/T 10 hrs=9 stations=320/9=35.5 hrsAverage man hours by stationsAlign sequences to assy.stations 1,Align sequences to assy.stations 2,Checking of parallel activities-locations and compatibility-part handling and lifting requirements Align sequences to assy.stations 3,189765432Beam paintingPipe paintingPipe cleaningWater Pipe Welding,pressure check123456789Test benchDisassemblyCleaningPaint repairShippingWorkstations and WIPOutlet box and oil tank preparationControl panel preparationBeam preparationCable preparationEngine preparation123456789Pulse line plan-Simulation123456789Validate the assembly sequences and timingValidate material presentation and in-house logistic processValidate Space requirement between the containers and for the subassembly preparation and presentationSelect the best way for moving devices for 2008 Working description Move the containers based on 10 hrs Takt time Keep 3 weeks standard lead timeScaffolding with wheels moves with container Container moving by handPull assembly line study Assembly ws.and sequencesAssembly LT 12.8 days+5 days from test to shipping 7-ways for layout design1.2-3.4.5-6.7.8.Golf ScoreLayout design#3Complete the layout with workstations and inside storage areasWorkstations in bay4Engines,Test bench123456789Assembly Layout planEngineControl boxControl panelsOutside storage areaTest benchShippingDisassembly cleaning repaintingAssembly Layout planOperator and space requirement1,Operators by skills2,Inside operations3,Outside storage space for 1 container unitRail systemDolliesFirst container on the lineAssembly of scaffolds 3 Containers on the line Working on the roof First container on the testline
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