Johnny Guilherme

Jeff you can set up an “assembly line” in which pull versus push together with different lots sizes which will lead you to the one piece flow. I have on may occassions done this exercise for training purposes. If you wish i can give you some more details.
regards
Johnny Guilherme
[email protected]

How about a sample per piece of equipment and then across the equipment types. You would have to identify the variables that make up your cycle time i.e. moves, loads etc and then place these on a “operations chart” in which you break down into 5 or 10 minute intervals. Then you will have to watch the equipment and mark down on your chart over say…[Read more]

There is nothing wrong with quick wins-sometimes the following the DMAIC approach can be long and tideous-many dont understand the stats and tools.
I too worked in the pharmaceutical for many years and people got excited about quick wins.
Johnny Guilherme (BB)
 

Could i get some of those videos as well posted to jguilhermeat consol.co.za
much appreciated
Johnny

Andy Hi i am not quiet sure what is your objective in what you have posted. But if i understand you correctly then what i suggest is that you define each of the processes per the variaty of products you have. Then you will have to do a time study on each of the processes i.e. time each process over a good period of time and try to rate the worker…[Read more]

Andy
You have to get a baseline cost (for direct labour) and a time study will help here. Thats why understanding the time it takes to make a product is important from a direct labour point of view. Remember unit costs are made up of direct labour, indirect labour, overhead costs and material costs. The question that was posed originally was ab…[Read more]

If you want to reduce WIP, you could start by reducing the batch size (thats if it is possible). Leadtime is a function of the batch size. By doing this make sure that you look at set up times within your process. If you can reduce set up times then you can look at reducing the batch size. Remember if you can save on 20% of your set  up then you…[Read more]

Whiskeydelta i am not sure that i understand your problem. If you have measured the necessary times for each of the activities/processes on the line, then what you must do is try to balance the line as best you can, (by maybe assigning more people, putting tasks togther etc). Once you have done that then you look at the slowest operation in that…[Read more]

The control limits shoud have been calculated once the the PC (process capability) study was conducted. Prior to the process capability study you should have done some sort of optimising on the process in order to determine the optimal control settings (together with upper and lower ranges for these control settings). The way i understand it you…[Read more]

Mike our reactor project is taking shape. We are busy with the conceptual design. I have an external consultant (expert on vacuum) to help with the design. Implementation will happen during the course of the year. I see that you are having a seminar on six sigma at the Castle in Kahalami. I would love to have attended, but your costs per delegate…[Read more]

I agree with your opinion. How is it going Mike, long time no hear. Are you still in Rustenberg??
regards
Johnny Guilherme

New-VGB
Do you mean location?? i.e. in what part of the world am I???
Johnny

Mike
What about the big “5” you have seen in SA.
By the way i have taken the idea you gave me up on our granulation area a little further. I am looking at drums on wheels with an exit pipe at the bottom of the drum. They can dispense all the powders into one drum (as apposed to 7 steel containers) and take it up and get it connected to the…[Read more]

Mike
Thanks. I did try to contact Ulices but was not successful. I will try again.
Regards
Johnny

Mia hi thanks for responding.
The situation with this line is that we already are doing “short” runs according to our production manager. The issue lies in having the machine down for such long periods of time and hence at times having to run overtime because of shoratge of capacity. One obvious way of reducing the setup(i.e.an immediate…[Read more]

Darth
Where can one get more info on Gage R&R. I must admit I read your posting but it did not mean much to myself. I looked on the blue next to this discussion forum. Unfortunately I could not get in. i.e. what doe sit mean and where can one apply it.
Johnny

Mike
Give us the answer. Maybe because of the “edgyness” the respective people are not posting. Maybe they are just busy working. I keep wondering about the edgyness-were you guys at school together or what???
Johnny

TBB
Its seems like some of your benefits are not tangible. You could assess though what each customer spends on average. Then look at your capacity for customers i.e. how many you handled before the improvement. Now after the improvement how many more customers can you handle. The extra customers that you can now accomodate times what each…[Read more]

Hi Mike
You are so right about the “lowering of the water and exposing the rocks”. Back at my previous position, when kanbans were introduced and the WIP suddenly dropped lots of process issues came up and guess what people did not know or have any tools to help in sorting out those issues. The reaction was build up the WIP again and forget about…[Read more]

I have already. He has been at my home and got me some literature on six sigma- “The six sigma way team fieldbook” and another two. I am busy reading the six sigma way team fieldbook and it seems really good. He will still be in SA for a while and I have plans for him to come a give a talk to our CEO and other directors on six sigma.
regards