1、Slow Cooker Productivity ImprovementModel Line Report With PCBAPage 2ConfidentialObjectives:-Combine workstations to minimize loading/ unloading time and WIPImprove productivity & reduce DL costShorten line to improve line balanceShorten line to reduce changeover time No pallet/ carton to reduce

2、 material inventory and get better 6SExample 1 _ Final Assembly - Slow Cooker Model Line ConceptPage 3ConfidentialMain Assembly Line Improvement result 改善前：改善前：Use belt lineT/T is 19 sec, 31 operators per lineHourly Output: 164 units per hourWaste space, more reworkHigh line changeover time loss Bef

3、ore ImprovementAfter Improvement改善后：改善后：T/T is 40 sec, 26 operators / two linesHourly Output: 156 units/hour / two linesSave spaceReduce line changeover time Page 4ConfidentialIdentify T/T & Ideal Operator NumberTakt Time: Based on customers demand, the time phase to make one productOld Standard

4、19sTakt TimeNew Standard40sOperator per Line31 Operators26 Operators19 sec T/T at present, more non-value added time during operation, and too many direct labors in a line which causes bad unbalance. Increase T/T properly, improve ratio of value added activity for operators, improve production effic

5、iency.Per overall analysis for operation elements and machine status, decide to choose 40 sec as new T/T finally.Page 5ConfidentialKaizen Result (Old Std Vs. New Std)Project: Slow Cooker Productivity Improvement & Operators Reduction (Model: SCCPVP550-B 7 Qt Slow Cooker) Before ImprovementAfter

6、Improvement Current After Improvement TargetMain Line Productivity (Units/Labor):164 Units / 31 Labors / 1 Line (5.29 Units/Lab)78 Units / 13 Labors / 1 Line OR 156 Units / 26 Labors / 2 Lines (6 Units/Lab) 13% Improvement78 Units / 11 Labors / 1 Line OR 156 Units / 22 Labors / 2 Lines (7.09 Units/L

7、ab) 34% ImprovementWIP Inventory (Units / Line):30 Units Per Line13 Units per Line 57% Reduction13 Units per Line 57% ReductionDL Cost :$0.2330 / Units$0.2027 / Units Save $0.0303 or 13%$0.1689 / Units Save $0.064 or 27%Expense Needed: $ 44K for 22 short lines ($2K/Line) 2011 Fiscal Year Saving: $ 8

8、6,922 (for Slow cookers)Page 6ConfidentialObjectives:-Reduce motion waste while take material from palletReduce changeover time Reduce material inventoryReduce space occupied Get better 6SEfficiency Kaizen- Use Trolley To Replace Pallet/CartonPage 7ConfidentialBefore ImprovementAfter ImprovementEffi

9、ciency Kaizen- Use Trolley To Replace Pallet/CartonPage 8ConfidentialKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolLayout improvement- One long line 31 operator - Two short lines 12 operator per line- Shorten time and easy to get - Motion studyEfficiency Kaizen- One long line chang

10、ed two short lineBefore ImprovementAfter ImprovementPage 9ConfidentialEfficiency Kaizen- Stations adjustKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolStations adjust- Two stations to PCBA panel-control- One station to PCBA panel control- Shorten time and easy to get - Motion studyB

11、efore ImprovementAfter ImprovementPage 10ConfidentialKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolProcess improvement- Two stations to asbestos and fix bottom cover- One station to asbestos and bottom cover- Shorten time and easy to get - Motion studyEfficiency Kaizen- Stations ad

12、justBefore ImprovementAfter ImprovementPage 11ConfidentialEfficiency Kaizen- Eliminate Waiting in Material Quality InspectionKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolCheck wrapper quality and remove PE bagIn off-line-A lot of waiting during wrappers quality inspection and remo

13、ve bag, low efficiency- High WIP - transport the main line after remove the protective membrane or PE bag in supermarket- Reduce production area to make clean ,reduce WIP and improve inspector efficiency.- Time studyBefore ImprovementAfter ImprovementPage 12ConfidentialEfficiency Kaizen-Eliminate Un

14、stable OperationKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolSeparate aluminum liner by warehouse team at supermarket- Unstable time to separate liner because of tight stacking, how to balance the line?- Huge line side WIP- Separate liner at supermarket and stack on trolley- Same

15、time to get the liner- Smaller space- Reduce inventory- time studyBefore ImprovementAfter ImprovementPage 13ConfidentialEfficiency Kaizen-Eliminate Unstable OperationBefore ImprovementAfter ImprovementKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolSeparate crockpot liner by warehous

16、e team at supermarket- Unstable time to separate liner because of tight stacking, how to balance the line?- Huge line side WIP- Separate liner at supermarket and stack on trolley- Same time to get the liner- Smaller space- Reduce inventory- time studyPage 14ConfidentialSpace SavingModify Carton Seal

17、ing Machine LayoutKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolShorten the packing operations movement and shorten the line-Two sealing machines are in one line located - Change the second machine to horizontal- Shorten the assembly line by about 1.7m- Motion studyBefore Improveme

18、ntAfter ImprovementPage 15ConfidentialKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolShorten time to get power cord- Place power cord on the table ,use a small heater to refrigerate- Place power cord in main line directly, use a blower to refrigerate- Shorten time to get the cord- 5S- Motion studySpace SavingModify Table LayoutBefore ImprovementAfter ImprovementPage 16ConfidentialKaizen TopicBefore ImprovementAfter ImprovementResultKaizen ToolShorten time to get b