Process Improvements in the Press Room

1
Process Improvements in the Press Room

• Presented by Scott A. Silverman

2
Challenges to Process Improvement

• Time
• People do not like change
• Dont see that there is a different and better
  way.
• Improvements in a Job Shop are more challenging
  than an OEM.

3
Tonights Presentation

• Making improvements in a job shop environment
• Improvements in the press room
• Reasons improvement projects fail

4
Customer Satisfaction

• Six Sigma is a quality program that when all
  said and done improves your customers
  experience, lowers your costs, and builds better
  leaders.
• Six Sigma accomplishes that by reducing waste
  and inefficiency and by designing a companys
  products and internal processes so that customers
  get what they want, when they want it, and when
  you promised it.

Winning by Jack Welch and Suzy Welch pages 249
- 250
5
Common Sense Approach to Process Improvement

• Assembly line manufacturing rather than batch
  manufacturing.
• Standardize and Simplify.
• Optimize resources.
• Think differently.

6
Faster

• From order receipt to the shipping door by better
  utilizing your present resources
• More orders in a given amount of time with the
  same resourcesmore profit
• Better quality, reduced costs, and customer
  satisfaction are all bi-products

7
Batch vs. Lean1000 Piece Order

• Batch

• Lean

Operation 1 200 Part/Hr.
Operation 1 1 part out every 18 seconds.
5.00 hours
Operation 2 300 Part/Hr.
Operation 2 1 part out every 12 seconds
3.33 hours
Operation 3 300 Part/Hr.
Operation 3 1 part out every 12 seconds 18 sec x
1000 pcs 3600 sec
3.33 hours
Total Hours 11.66
Total Hours 5.02
8
Better Utilize Your Resources

• Process improvement is not about new equipment it
  is about better utilizing the equipment and
  resources you have.
• Better utilization of your current resources
  forces you to find and eliminate waste.
• When current resources are fully utilized it is
  easy to cost justify new resources.

9
Standardize Simplify

• The E-Myth Revisited Why Most Small Businesses
  Don't Work and What to Do About It by Michael E.
  Gerber April 12, 1995
• Create a system that is well defined, easy to
  understand and constantly being improved.
• Standardize as much as possible to make
  repeatable and predictable results

10
Fresh Perspective

• It is difficult to that there may be a better way
  when you follow the same routine everyday.
• Get a fresh perspective from someone outside your
  company.

11
Press Room Improvement Projects

• Preventive maintenance
• Detecting quality defects as they happen
• Mistake proofing
• Make tools more reliable
• Reduce tool maintenance time
• Setup time reduction
• Automation

12
Preventative Maintenance

• Improves equipment reliability.
• Perform maintenance on your terms rather than
  when something breaks down at the least
  convenient time.
• Document the program as simply as possible.
• A clean organized press room contributes to
  efficiency and product quality

13
Build Quality into the Process

• Improve processes to give customers the parts
  they want without additional cost.
• Build quality into the process so that defects
  dont happen in the first place.
• Improvement costs can easily be justified if you
  look at the cost of inspecting after the parts
  are made.

14
Detect defects as they happen

• Electronics are very affordable.
• Many free training resources.
• If your process isnt reliable in the first place
  all you are going to do is keep shutting down the
  process.

15
Error Proof

• How we can prevent an error from happing again.
• Operator errors will happen again if you dont
  take preventative measures.
• Mechanical solutions.
• Electronic solutions.
• Always time and money to rework a job when the
  same mistake happens again.

16
Tooling reliability

• Tooling reliability is key to make your lead time
  predictable.
• Tooling breaks when you need it which leads to
  band aids instead of fixing the root cause.
• Program to get problem tools back to the tool
  room after the production run.
• Use sensors to prevent crashes.

17
Reduce Tool Maintenance Time

• Create a standard tooling component /design list.
• A tool should be able to be worked on by anyone.
• The more you standardize the less time that will
  be wasted trying to figure out how something is
  built.

18
Setup Time Reduction

• Video tape a number of changeovers.
• Tell people what you are doing.
• Tape enough setups to get a good cross section.
• Make sure the time stamp function is turned on.
• Review the videos and look for the following
• How long each setup takes.
• How much time is spent on Go-fetch-find
• How much time is spent making adjustments?
• Then evaluate
• What can be standardized?
• What can be pre-staged.
• How can adjustments be eliminated.

19
Automation

• Difficult to cost justify in a job shop unless it
  flexible enough to be used on different products.
  Look anyways.
• Brainstorm ideas without financial or
  technological restraints. Then refine.
• Think differently and dont be constrained by
  preconceived notions.

20
10 Reason Projects Fail

• Not creating a program
• Not getting operators involved
• Not following up.
• Not documenting
• Not being scientific
• Improving one area that has a negative effect on
  another
• New procedure or device that is not user friendly
• Project too universal
• Not sticking to the improvement program
• Giving up too easily

21
Everyone Plays a Part

• Everyone in the company plays a part in serving
  the customer.
• It is everyones job to eliminate waste and come
  up with ways to be more productive.
• Give solutions not complaints to upper management.

22
Global Economy

• Quick delivery and great customer service will
  give you a competitive advantage.
• Constantly improve and give your customers the
  consistent quality and delivery that they are
  looking for.
• Remember
• Get away from batch manufacturing.
• Standardize and Simplify.
• Optimize resources.
• Think differently.

23

• www.JaryEngineering.com
• 508-284-2153