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| SET UP TIME |
Before
|
After
|
Reductions
|
| 1. Press |
3hrs 20 mins
|
45 mins
|
78%
|
| 2. Canning |
1hr 45 mins
|
23 mins
|
78%
|
| 3. Capper |
58 mins
|
15 mins
|
75%
|
| 4. Extruder |
32 mins
|
6 mins
|
80%
|
| 5. P.C.B. Line |
1hr 10 mins
|
5 mins 30 secs
|
91%
|
| CELLS | Before | After | ||||
|
*
LT
|
**WIP
|
***OPS
|
LT
|
WIP
|
OPS
|
|
| 1. Metal Ass'y |
6hrs
|
8500
|
5
|
10secs
|
8
|
3
|
| 2. Lock |
48hrs
|
10,000
|
5
|
17secs
|
10
|
3
|
| 3. Bowl |
25hrs
|
600
|
4
|
90secs
|
15
|
2
|
| 4. Textiles |
6 days
|
3,000
|
15
|
1hr 30mins
|
30
|
6
|
| 5. Slippers |
3 weeks
|
10,000
|
5
|
48secs
|
10
|
4
|
| * LT - Lead Time | **WIP - Work in Progress | ***OPS - Operators |
| TPM | Downtime Reduction | Defects Reduction |
| 1. Press |
63%
|
46%
|
| 2. Wrapping Mchn. |
48%
|
31%
|
| 3. Rim Line |
32%
|
60%
|
| 4. Strip |
58%
|
52%
|
| 5.Plastic Extruder |
72%
|
60%
|
| KAIZEN | |
| 1. Ladle faults saving | £50,000 per year |
| 2. Bottle damage | -60% |
| 3. Order lead time | 4 days to 3hrs |
| 4. Moulding wastage saving | £35,000 per year |
| 5. Friction stay production increase | 800/hr to 1200/hr |
| POKA-YOKE - 'O' DEFECTS |
| 1. Lock Manufacture |
| 2. Strip |
| 3. Control Assembly |
| 4. Electronic Assembly |
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All materials on this site are protected by International Copyright Laws. Reproduction in any form is prohibited without prior written permission. All Rights Reserved.
