xxxxxxx

J&A Shelf Lean Implementation

8/23/2007 Lead Time Analysis
Robert West
Total
Process Step Description Qty. VA NVA RNVA Que Notes
Time
Shear 1614 51 714 900

Punch
Manufacturing
Inspection (Punch)
29790

2700
51

1
14790 14400

2700
600 (51 Parts

LC1212 Laser cutouts 1Mln 10Sec 4170 51 3570 600

Brake Form Draw Flanges 4020 51 3060 960

Roll 2X 1320 51 1020 300

RETAP 4-40 2295 51 2295

laser pofile 9537 51 9537

Deburr 1410 51 510 900

joggle flange mounting flanges 6330 51 1530 4800

RG100 LANCES 90SEC 5610 51 4590 1020 Should be joggle not hem

RG80 3 SHORT FLANGES 30 SEC W/Special Special Backup Req 2610 51 1530 1080

Drill 16461 51 2601 180 13680

Haeger 618 Hardware Emboss 11 Places 2634 51 1734 900

FHS-M3-8 11X Setup Hager HPC Run 40 Sec 4260 51 4080 180 2 PEOPLE

FHS-M3-12 8X AND FHS-M3-8 1X Run 30 sec 1590 51 1530 60 2 PEOPLE

Form Long Flange W/custom Backup and End Flanges 12120 51 3060 5760 3300

Weld tabs, tack hdwr, fuse bracket 5Min 30sec 60030 51 16830 43200

Plate 288000 172800 115200 Inspection rejection and reinspection 2 + days

Straighten divider 1530 51 1530

810 51 510 300

Silkscreen 5400 51 4500 900

1500 51 600 900

6 ea B,C,D,E 6150 51 4590 1560 Vipros 345-SU 26 Min-R -?9MIN 20 SEC

6 ea B,C,D,E 10110 51 7650 2460

510 51 510

2 Joggles + 1 bend 0 51 B RG35S - SU 3.5HR- RUN 21 Sec .

Flatten Extrusions too high hitting on die 1110 51 1110 Exta op Flatten Extrusions- SU 10MIN -10Sec ea. no DMR !

Retap 7 extruded holes 690 51 690

Plate 172800 51 172800

NESTED WITH "B"

510 510

NESTED WITH "B" NESTED WITH "B"

510 510

172800 172800

NESTED WITH "B"

510 510

6684 51 2244 4440 E RG80 - SU 1hr 14 Min- RUN 44-Sec . 4 short flanges

172800 172800

Assembly 17130 51 16830 300

1275 1275

6120 51 6120

Seconds 1035450 106233 62037 691200 175980

Minutes 17258 1771 1034 11520 2933
Hours 287.6 29.5 17.2 192.0 48.9
Shifts 35.95 3.69 2.15 24.00 6.11

Created by R West Sheet _____ of _____ JA Manufacturing Confidential

 Schedule Mu

Metal
Supplier

Daily

1 2 3 4 5 6 7 8

Shear Punch Laser 8 Form Roll 2X RETAP 4-40 laser Deburr

cutouts only around pofile
cutouts only

People ( 1) (1) ( 1) ) ( 1) ) ( 1) (1) ( 1) ( 1)

1 1
Cycle Time 5 290 70 ( 60 ( 20 45 187 10
Change Over 15 Min 5 min 10 min 16 min 5 min 10 min 10 min 15 min
Transfer Qty (Lot) 30 30 30 30 30 30 30 30
Available Time 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200
Shifts 2 2 2 2 2 2 2 2
0.9 0.9 0.9 0.9 0.9 0.9 0.9
5 290 70 60 20 45 187 10

Flatten
Extrusion
Punch 6 Laser 6 s too Retap 7
Shear ea ea Deburr Bend extruded Final Ins
B,C,D,E B,C,D,E high holes
hitting
on die

People ( 1) (1) ( 1) ( 1) ( 1) (1) ( 1) ( 1)

Cycle
C/O

Part "C"
Punch and Deburr Bend Final Ins Move to
Laser Weld
with "B"

People ( 1) ( 1) (1) ( 1)

Cycle
C/O

Part "D"
Punch and Final Ins
Laser Deburr Bend Plate
with "B"

People ( 1) ( 1) (1) ( 1)

Cycle
C/O

Part "E"
Punch and
Laser Deburr Bend Plate Final Ins
with "B"

People ( 1) ( 1) (1) ( 1)

Cycle
C/O
 Discreet orders

Deman 700 per month

Schedule Multiple points 30 ea. Transfer qty
2 shifts (most ops)
Nov = 20Work days
700 / 20 = 35 Per day customer demand (Takt)

9 10 11 12 13 14 15 16 17 18

joggle RG100 RG80 3 Drill Haeger 618 FHS-M3-8 FHS-M3-12 Form Long Weld tabs, Plate
flange LANCES SHORT Hardware 11X Setup 8X AND Flange tack hdwr,
mounting 90SEC FLANGES 30 Emboss 11 Hager HPC FHS-M3-8 W/custom fuse
flanges SEC Places Run 40 1X Run 30 Backup and bracket
W/Special Sec sec End 5Min 30sec
Special Flanges
Backup Req

( 1) (1) ( 1) ( 1) ( 1) (2) ( 1) ( 1) ( 1)

30 90 30 51 34 40 30 60 330
80 min 20 min 18 min 3 min 15 min 3 min 1 min 96 min 5 min
30 30 30 30 30 30 30 30 30 30
55,200 55,200 55,200 55,200 55,200 27,600 27,600 55,200 55,200
2 2 2 2 2 1 1 2 2
0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 3 0.9
30 90 30 51 34 40 30 60 330

Plate

( 1)
reet orders

Tyco

omer demand (Takt)

Daily

19 20 21 22 23

Straighten Hardware Silkscreen Assembly Package

divider
SOS-84-
1-14 Pem
1X

( 1) (1) (1) ( 1) ( 1)

30 30 60 240
0 5 min 15 min 10 min
30 30 30 30 30
55,200 27,600 27,600 27,600
2 1 1 1 1
0.9 0.9 0.9 0.9
30 30 60 240 0

Lead Time 22.86Days

Processing Time 1742/60 s29.03Min

 Tyco xxxxxxxx15 Shelf Future State

Deman 700 per month

30 ea. Transfer qty
Schedule Multiple Points 2 shifts (most ops)
Nov = 20Work days
700 / 20 = 35
Metal
Supplier

Daily

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 1 1 1 1 1 1 1 1 1 1 1
Shear Punch Laser 8 Form Roll 2X RETAP 4-40 laser Deburr / joggle RG100 RG80 3 Drill Haeger 618 FHS-M3-8 FHS-M3-12 Form Long
cutouts only around pofile Flatsand flange LANCES SHORT Hardware 11X Setup 8X AND Flange
cutouts only mounting 90SEC FLANGES 30 Emboss 11 Hager HPC FHS-M3-8 W/custom
flanges SEC Places Run 40 1X Run 30 Backup and
RG80 3 Sec sec End
SHORT Flanges
FLANGES 30
SEC

People (1) (1) (1) ) (1) ( 1) (1) (1) (1) (1) (1) (1) (1) ( 1) ( 2) (1) (1)
1
(
Cycle Time 5 360 70 60 20 45 187 10 60 90 30 51 40 30 60

Change Over 15 Min 10 10 min 16 min 5 min 10 min 10 min 15 min 80 min 20 min 18 min 3 min 15 min 3 min 1 min 96 min
Transfer Qty (Lot) 30 30 30 30 30 30 30 30 1 1 30 30 30 30 30 30
Available Time 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 55,200 27,600 27,600 55,200
Shifts 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 2
0.9 0.9 0.9 0.9 0.9 0.0 0.9 0.9 0.9 0.9
5 360 70 60 20 187 60 90 0 40 30 60

Check to Increase
Eliminate see if we the hole
Eliminate this step can punch Try to size for deltete
this Increased Eliminate eliminate the this op
operation by 70 sec this step (increase more to micro hardware run on
buy 48 x + 5 min Combine H-Limit) get time joints combining to 3 MM punch
30" 16ga for setup with 2 cut dies down to and this 9 and 11 (we are operation
etc 90 sec or
blanks set up 2 operation tacking #1
lasers them in
anyway!!
 Discreet orders

ansfer qty
Tyco

Per day customer demand (Takt)

Daily

Future
17 18 19 20 21 22 23 # of Ops 19

1 1 1 1 1 1 1
Weld tabs, Plate Silkscreen Straighten Hardware Assembly Package
tack hdwr, divider and SOS-84-1-14
fuse Hardware Pem 1X
bracket SOS-84-1-14
Pem 1X

10

(1) ( 2)
2
( 2)
2
( 1) (4)
2
(1) Lead Time 13.80 Days
( ( (
330 60 60 30 60 Processing Time 1492 /60 s 24.87 Min
5 min 15 min 0 5 min 10 min
30 30 10 30 1 1 30
55,200 55,200 27,600 27,600
2 1 2 1 1 1
0.9 3 0.9 0.3 0.0 0.0
330 60 60 60 0

Add
Helper No Data?
and for this
reduce operation
transfer Combine 4 People
qty to with 20 with
oven to
10 parts Combine to cordless
maybe with 21 balance drivers
setup with to
silkscree balance
screen n line
process
nearer
oven to
lessen
transport