Overtime Reduction

Green Belt

Project Leader: Jennifer Redden

Champion: Kristin Marra
Team Members:
Ruth Morgan (Supervisor)
Leslie Nourse (Key Operator)
Chris Zawadzki (Process Engineer)
Dan Johnson (Set Up)
Deb Smith (Quality Control)
Rob Pattacciato (Manager)
Chris Becker (Kanban)
Project Time Frame: 07/07 – 10/07
 What To Do

• Narrow the focus of the project

• Identify the causes of Overtime

• Prioritize the causes of Overtime

• Use the Lean Six Sigma Tools to achieve

project goal
Process Flow for MS2/LN Armature Cell
Fishbone Diagram for MS2/LN Armature Cell

Measurement Method Machine

*Cell Staffing vs. *Oven

Schedule Build -not run 24/7
*Tank Pins
-sanding pins

*Oven
- repeat/reproduce

Overtime

*Training

*Organization
Vacation -schedules

Quality
Call-ins -solder/paper

Scrap Rework

Manpower Materials Environment

 Areas to Focus on:

(1) Oven
(1) Get running 24/7
(2) Make sure we are running to spec or change spec (if necessary)
(3) Repeatability and Reproducibility
(2) Cell Staffing vs. Schedule Build Work Schedules
(1) Make sure numbers are achievable
(2) Efficiency – are they hitting the numbers
Cell Staffing Training
(3) Scheduling Shared Cells
(1) Design
(2) Implementation OT
(4) Training Reduction
(1) Get all SOP/CP updated and on boards
(2) Key Operator – Complete OJT’s Oven Operation Kanban
(3) Key Operator – Begin Training in each cell
(5) Hairpins
Hairpin Consistency
(1) Reduce Time/Save Money
(2) Reduce Rework/Scrap
(6) Implementation of Kanban
 FOCUS 1: OVEN

800
800

700 700

600 600

500 500

# of Units
# of Units

400 400

300 300

200 Oven Output 200 Oven Out put

Goal
Goal
Linear (Oven Out put )
100
100
Oven Output Before Linear (Oven Output) Oven Output After
0 0
07

07

07

07
7

07

07

07

07

07

07

07
00

00

00

00

00

00

00

00

00

00

00

00

00

00

00

00

00

00
20

20

20

20

20

20

20

20

20

20

20
/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2

/2
2/

4/

6/

8/
27

29

31

10

12

14

16

18

20

24
22

26

28

1/

3/

5/

7/

9/

1/

3/
9/

9/

9/

9/

/1

/3

/5

/7

/9
8/

8/

8/

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9/

9/

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/1

/1

/1

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/1

/2

/2
10

10

10

10

10

10

10

10

10

10

10

10
Date
Date
1. Inconsistent Temperature vs. Specification 1. Consistent Temperature within Specification
2. Downtime for breaks, lunches, & changeovers 2. Staggered breaks, lunches, & changeovers –
3. Curing Variances lead to Quality Issues oven is always attended

4. Increased scrap & rework 3. Curing is Consistent yielding high quality

products
4. Reduced scrap & rework
 FOCUS 2: STAFFING/BUILD

Welder Efficiency - Sept 07 Press Efficiency - Sept 07

180 250

160

200
140
% Efficient

% E ff ic ie n t
120
15 0
100

80 10 0

60

50
40

20
0
0

D at e
Date

Oven Efficiency - Sept 07

180

160

140
% Efficient

120
1st Shif t

100 2 n d Shif t

80 3 r d Shif t

Goal
60
Lower Limti
40
Upper Limti

20

Date
 FOCUS 3: SCHEDULING

BEFORE AFTER
LEECE Line 10-8-07
Frame Shift Hsg Nose Hsg
QTY MODEL # DAY SHIP Arm Shafts Field Basket Brush Drive
F & F Assy Shift Assy Nose Assy
M017225364 M165102553 M005102565
130 M0017705ME MON 460 M002102564 M064102562/R M018225395 M008225396 852957
M016225369 M777102554 M014102566
M017225364 M165102553 M005102565
78 M0017705ME TUES 460 M002102564 M064102562/R M018225395 M008225396 852957
M016225369 M777102554 M014102566
M017225364 M165102567 M005102577
52 M0017400ME 460 M002102564 M064102562/R M018102515 M008103330 852959
M016102516 M777102569 M014102594
M017225364 M165102567 M005102577
52 M0017400ME WED 460 M002102564 M064102562/R M018102515 M008103330 852959
M016102516 M777102569 M014102594
M017225279 M165102567 M005102577
78 M0017507ME 460 M002225333 M064225060/A M018102530 M008103330 852959
M016102531 M777102569 M014102592
M017225279 M165102567 M005102577
32 M0017507ME THURS 460 M002225333 M064225060/A M018102530 M008103330 852959
M016102531 M777102569 M014102592
M017225364 M165102567 M005103900
98 M0017730ME 460 M002102564 M064102562/R M018225395 M008225160 852957
M016225369 M777102569 M014103902
M017225364 M165102567 M005103900
130 M0017730ME FRI M002102564 M064102562/R M018225395 M008225160 852957
M016225369 M777102569 M014103902

Total 650 Date Printed 10/3/2007

1. Constant Supervisor Direction 1. Customer Demand Drives

2. Customer Demand at Risk Production – Prioritization!
3. Shared Cells = bottleneck 2. Workers’ skills matched
4. Mis-match of workers with job with operations
5. Unpredictable changeovers 3. Shared Cells poised to
meet downstream demand
4. Overall ORGANIZATION &
PREDICTABILITY
 FOCUS 4: TRAINING

Key Operator Training

10/26 Darren & Chris complete all SWP’s (Standard Work Procedure)

11/9 Deb completes all of Leslie’s OJT’s (On the Job Training Form) for the MS2/LN
Armature Cell

11/16 Leslie completes Operator OJT’s for Press Laminations to Shaft and Cut and Insert
Cell Paper into Lamination Slots

11/23 Leslie completes Operator OJT’s for Cut Insulation Paper to Proper Length, Cut and
Form Hairpins and Insert Hairpins and Add Insulation Paper

11/30 Leslie completes Operator OJT’s for Twist Hairpins, Trim Hairpins to Proper Length,
Press Commutator over Shaft

12/7 Leslie completes Operator OJT’s for Weld Hairpins to Commutator

12/14 Leslie completes Operator OJT’s for Hi Pot and Stamp Armature, Tape Hairpins,
Analyze Armature Welds, Varnish Armature and Cool, Check and Straighten Armature
and Lathe Commutator and Check for Shorts
 FOCUS 5: HAIRPINS

Observations Possible Solutions

• Operators sanding pins on
straight time and overtime
• Hand sanding is inconsistent &
timely – causes fallout down the
line
• Automate Sanding – working on
with Engineering
• Outsource Sanding – used to do
and still had to sand pins when
received

Tank Pins

Hand Sanding Machine (pre-stripped) Machine (fully coated)

Operator Belt Sander/Pinners Pinners Pinners

# of Pins (25 Armatures) 675 675 675

Pins/Min (Approx) 3 5.5 3.5

Min/25 Armatures 225min (3hr 45min) 123min (2hr 3min) 193min (3hrs 13min)

Pin Machine (Approx Pins/Min) 26pins/min 26pins/min 26pins/min

Time Saved with Machine 0 102 (1hr 42min) 32min

FOCUS 6: KANBAN
 Target for OT = Budget

ANNUAL 7,000
Overtime Target
25%

SAVINGS 6,000
20%

$50K 5,000

15%

% of Labor
4,000
OT $

3,000
10%

2,000

5%
1,000 Plan OT
Actual OT
- 0% Plan %OT
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Actual %OT
 Project Summary

•Oven – Running the oven continuously produces better quality armatures and reduces the EOL failure.
Also, produces consistent product, reduces rework/scrap and gives over 5hrs more of available production
time a day.
•RECOMMENDATION: Maintain temperature to spec and eliminate downtime.

•Cell Staffing – Ensures that the operators time is being properly utilized
•RECOMMENDATION: Match production targets with cell staffing plan

•Schedules – Ensure we are building what the customer needs when they need it. Also, will help
recognize part shortages earlier so that they can be dealt with in a timely manor.
•RECOMMENDATION: Implement & Utilize Daily Schedules as supplied by Customer Service

•Training – Ensures operators are doing their job correctly and consistently across all 3 shifts. Also, will
reduce rework/scrap if operators are properly trained.
•RECOMMENDATION: Verify Operator Training & Cross-Train within Cell

•Tank Hairpins – Getting new equipment will produce more consistent product faster. It will save almost
2hrs of production for every 25 armatures and reduce rework/scrap.
•RECOMMENDATION: Implement Automation Equipment – *Purchased on 11/28/07*

•Kanban – Workplace will be more organized and will only be building product we need.
•RECOMMENDATION: Continue with Implementation & reproduce throughout Starters