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68rs327

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Viewing 17 posts - 1 through 17 (of 17 total)
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  • #202301

    68rs327
    Participant

    Our company has several continuous improvement associates. The person described led this groups activities as their supervisor. A proper name for this position other than manager would be?

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    #201994

    68rs327
    Participant

    Let’s try this again.
    1. Process “A” is a machining process. OEE ranges anywhere from 50% to 70%, due to massive amounts of downtime. I know we need to work on uptime, but engineering can’t seem to fix the downtime. Changeover time is 45 minutes. They run 500 pcs. then changeover, per our shipping dept. Cycle time per piece is 30 seconds. The variation in uptime is what kills things.

    2. Process “B” is a painting process, it’s uptime is 90% and OEE ranges from 90-95%. Cycle time on this process is 30 seconds. No changeover time.

    3. Process “C” is an assembly process. Their OEE ranges from 50% to 70%. Their change over time is 30 minutes. Their cycle time is 30 sec to 37 sec. depending on what part they are running. All three process run the same 5 models. This process runs 500 pcs and changes over.

    4. I am wanting to put in a store to feed process “C” because it may not be running the same model that process “A” is running.

    5. Route pick up and deliver from “A” to “B” to “Store” to “C” is every 30 minutes.

    I believe there is enough info here to recommend a store size?
    If not, can someone post the calculations on how to calculate a “Store” size.
    I know it calculated off cycle time, lead time, OEE, fluctuation, Etc.
    I need the calculation….

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    #201990

    68rs327
    Participant

    I need to clear up the confusion.
    The cycle time of the machine is 30 seconds, but the pickup delivery route is 30 minutes. And the machine changes over every 500 pieces. Machine A runs 5 models as does B and C, but they run all the same model. Machine B runs the parts that A does, material delivery is parts are picked up at A and dropped off At B to be painted. Their cycle time is the same.
    Parts are picked up at B and delivered to C’s future store.
    Now, Machine cell “C” also runs the same 5 models as “A” but they may not be running the same model at the same time… this is why I need a store. Uptime on “A” and “C” is anywhere from 50 – 65%. Scrap on “A” is about 3% and scrap on “B” is less than 1%.
    If you need more info. please let me know.

    If the problem is to difficult to calculate without seeing the process… Can someone give the calculations on how to calculate a “Store Size” .

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    #201984

    68rs327
    Participant

    Thanks,
    I’m anxious to see if anyone can help. I know this is a common thing in a factory setting. I think I have enough information for someone with experience to walk me through it.
    Thanks,

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    #201982

    68rs327
    Participant

    No Ideas?

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    #201114

    68rs327
    Participant

    I did a search before posting … I was hoping to get opinions on which material was best from those with experience with MIF Maps or Value Stream Mapping Material.
    Which is the best study guides, software and other training material.

    Thanks for all your help.. but by saying do a Bing search didn’t answer the question.
    And provided NO help. I wasn’t asking for anyone to do my “Homework” …
    I was seeking opinions from those with experience with the material… I presume you have no experience with this material.. not sure why you felt the need to reply to the post…
    But, thanks anyway for the negative opinion.

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    #201091

    68rs327
    Participant

    I knew it wasn’t six sigma related.. I was hoping on of the lean managers had a similar situation. Thanks

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    #200223

    68rs327
    Participant

    null

    null

    board

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    #199748

    68rs327
    Participant

    Thank you all for the replies. Since I am not paying for the training, I will go in with an open mind and see if the Kool Aid is worth drinking. My company has issues on many lines with fluctuation in the process… Machine Downtime, work balance of the line, small parts delivery issues… This is what I am currently working on to help improve output. The new manager said I should be working on scrap reductions. Scrap on this line is .02% . I tried to explain that if the line doesn’t produce parts, scrap doesn’t really matter at this point. Improving output to meet customer demand is first on my list. The manager said that’s not the job of the lean group, that’s the engineering departments job… I disagreed again. So needless to say, this isn’t going well… But, if all this manager want’s me to do is focus on the .02% scrap, then so be it. And if Shainin is what the manager want’s us to work with and put Six Sigma to the curb, then I guess that’s what we will do for now. I don’t see this manager lasting very long.

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    #199738

    68rs327
    Participant

    Mike,
    The 68rs327 is a 1968 Rally Sport Camaro with a 327. It’s an all original 4 speed car… Anyway, I agree with your statement. I am up to learning new things and starting soon, I will be trained in Shainin “Red X”. I am sure like anything else, it will have good and bad points. I have learned that most all lean thinking is very similar. Six Sigma and TPS have similar tools and similar mindsets. I am sure Shainin is no exception. It just bothers me that Shainin is being sold to us and I don’t think we need it when we already have all the tools in place to do lean activities. Shainin training is Really, Really, Really Expensive. But, I may be wrong and it may be the best thing since the ballpoint pin?

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    #199723

    68rs327
    Participant

    Strayer,
    Thank you, good advice on the train station. :)
    To be honest, I never heard of Shainin or Red X, before this manager showed up.
    No one in the company has either… But the manager sold it and now we start training soon. They hired the Shainin Corp. to train us, and it is Very Expensive. Thankfully I am not paying for it. So, I am up for free training, always willing to learn new things.

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    #199643

    68rs327
    Participant

    I did search… I did not see a discussion that answered my specific question.
    I specifically wanted to know if the Six Sigma vendors on this directory were accredited to award Six Sigma Certification.
    Specifically the vendors on the attached link…..

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    #199517

    68rs327
    Participant

    Getting the supervisors involved has been an issue.

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    #199114

    68rs327
    Participant

    Devender Malhotra ,
    thank you very much for your reply, I agree with your comment.
    Our lean team in the past always took the fastest cycle out of 40 cycles and stated this as the cycle time of the assembly lines. Our sales group sold capacity of the line based off this at 100% efficiency. Now our problem is we can’t produce enough based on the information our sales team was given. This has put us into 7 days a week when the line has any downtime. This leaves us no room for PM work, so if the line goes down, we put a band aid on the problem because we can’t afford to shut the line down to fix properly. The band aid’s keep breaking which causes a snowball effect. This has caused us to expedite shipments to customers so we don’t shut them down. So, with the overtime cost for Saturday/Sunday work and the cost of expedites, we are loosing money, a lot of money. Now management is saying speed the lines up, reduce the downtime and get profitable….. Easy to say, hard to do under the current conditions.
    I am trying to reverse this thinking, but it has proven to be difficult.

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    #199103

    68rs327
    Participant

    Update: The company is warming up to the idea of the cycle time adjustments needed.
    Also, They are wanting to put a Production Display on the assembly lines. The display needs to show “Shift Production Target”, “Hourly Production Target”, “Running Production Output Per Shift” and “Running Hourly Output”
    Have any of you used a display like this and do you know a good supplier in the USA?
    I found this company http://www.vorne.com/xl/xl600-lean-manufacturing-tool.htm
    Any of you familiar with this product?
    I researched the web, and found only a few companies that had these products.

    Thank again.

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    #199087

    68rs327
    Participant

    Thank you all for your replies, helped a lot.
    I thought I knew the answer, you all gave me peace of mind with your replies.
    I am going to talk with management and see how they want to move forward with this. I hope we can discuss this with our suppliers, who are the automotive industry. Sometimes they are a little hard to deal with.
    Thank you again.

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    #199078

    68rs327
    Participant

    The problem we are facing is over the last 10+ years the company has based their sales on the cycle times they were given for the assembly lines. They based the cycle times off the Lowest time in 40 cycles. This has caused the company to over sell their capacity, which has caused shortages to customers and 7 day week work. Our machines are 10 to 20 years old, which are not as reliable. On top of that they based the cycle times off one worker and taking their lowest cycle time. Then on top of that, they have started rotating operators on the lines every two hours. They weren’t thinking about through out the day people get tired and begin to slow down, they also didn’t think about the rotation every two hours and the person that was timed many be faster than the person who will be running the machine the next two hours. We work in 4 person work cells and have a lot of manual assembly work.
    My problem is: How do I change this and what is the proper way to determine the cycle time of the line with the stated conditions. If I were only timing machine, this would be easy, if everyone was a robot, this would be easy. But we have a Lot of manual assembly work with people being rotated every two hours. So operator “A” may be slower or faster than operator “B”, “C” or “D”. The second question is, how do we tell our customer that our cycle times were wrong and we over sold our capacity? On top of ALL this, this is a Japanese company who preaches TPS which isn’t a bad thing, but the way we have been taught to do cycle times and taking the lowest cycle, no matter who’s running the machine will be difficult to change. They will say “Kaizen the process to where everyone can do it the same at the same speed”,, but in reality people are not robots and some people are just faster than others and are not robots.

    Thank you

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Viewing 17 posts - 1 through 17 (of 17 total)