Kaizen

1
Kaizen 645

• Manufacturing Engineer Chris Thompson
• Operator Tony Seidl
• Supervisor Tim Tipple
• Maintenance Ted Baccam
• Safety Coordinator Eric LeConte

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Box Sealing Tape Dispenser
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Team Goals

• One piece flow
• Pull cell design
• Reduce cycle time by 50
• Reduce cost by 10

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Flowchart
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Current Costs

• Selling Price 19.17
• Mfg Cost 11.50
• Labor Rate 30/hr. including fringe benefits

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Current Process
All Parts Shown
Assemble Cutter Housing
Insert O -Ring
Insert Grommet
Assemble Wheel to Base
Insert Tongue
Screw Cutter Housing to Base
Assemble Handle to Base
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One Man Cell
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Alternative Methods
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Evaluation Matrix
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Best Alternative Processes
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Two Man Pull Cell
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Justification
OLD (One Person)
NEW (Two Person)

• CT 208 sec/unit
• Labor Cost 1.73 /unit
• Labor Hours / year 4000 hr (69,232 units per
  year)
• Material Costs
• Handle Bolt Nut 0.05 /unit
• Screws 0.02 / unit
• Total Cost 124,617.60 / year

• CT 71 sec/unit
• Labor Cost 1.18 / unit
• Labor Hours / year 2731 hr(69,232 units per
  year)
• Redesign Handle Die 1000
• Snap Fixture 300
• Material Costs
• Snaps 0.002 / unit
• Total Cost 83,132.23 / year

Total Cost Savings 41,485.37
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Kaizen Team Cost

• Time 12 hr / person
• Rates Engineer 40/hr Safety Coor. 35/hr
  Others 30/hr
• Total Project Labor Cost 1980.00

14
Summary of Team Goals

• One piece flow Achieved
• Pull Cell w/ Kanban Design Achieved
• Reduced Throughput Time by 32( Old CT 208 sec
  / unit vs. New CT 71 sec / unit )
• Reduced Cycle Time by 66
• Reduced Total Cost by 33