Final_Presentation_Denny_Kramer (1)
- 1. Intern Final Presentation Denny Kramer, Lean Manufacturing Engineering Intern August 5th, 2015 POLARIS INDUSTRIES INC. Ɩ Spirit Lake, IA
- 2. 2 Background Denny Kramer, Intern Presentation Summer 2015 College: Iowa State University – Mechanical Engineering Graduation: December 2016 Hometown: Earling, Iowa Past Work Experience: Kinze Manufacturing and Agriland FS Hobbies: Sports, Boating, Outdoor Activities, Helping on Family Farm
- 3. Lean Support – Day to Day Projects Problem Situation: Reduce Downtime on the Slingshot line Utilized Lean Tools (A3) and problem solving methodology to identify Non-Value Added Work Content Worked with Operators to resequence their Standard Work Coordinated with cross functional team to improve material presentation Before After Problem Situation: Reduce tapping on Slingshot line Kaizen Team Member - Helped collect and analyze data Problem Situation: Develop tooling for MY16 Slingshot launch Designed and implemented new battery bracket holder 3Footer Here Kaizen & NPI Support
- 4. A3 Process Utilized - Station 5711 Lean Tools (Spaghetti Diagram) & Station Observations Operator Input - what they did not like about their process (5 why’s) Created new material flow rack and parts tray Redesigned station layout 4Denny Kramer, Intern Presentation Summer 2015 ImplementationApproach Before After
- 5. A3 Process Utilized - Station 5711 5Denny Kramer, Intern Presentation Summer 2015 Rebalance StationFollow Up on Results Space & Time SavingsBefore & After PCT Repeated A3 Process for 20 stations Adjusted rack/layout until operator was happy with changes Opportunity to rebalance more Standard Work to the operator 0 100 200 300 400 500 600 Before After Value Added Walking Unpacking PCT 0 100 200 300 400 500 600 Before After Value Added Walking Unpacking PCT
- 6. Lean Manufacturing Team Results Cost Savings Before After Metrics May Avg. July Avg. % Improvement Annualized Savings Delivery Incease 38.1 42.4 11.5% 4,367,833.80$ Downtime Reduction 80 46 43.0% 344,926.88$ Sum of Cycle Reduction 27204 24612 9.5% 202,494.23$ Labor Reduction 9,840.67$ 9,397.96$ 4.5% 110,677.98$ Total 5,025,932.90$
- 7. Dislikes Likes/Dislikes Fast paced work environment Treated as valued team member Operators were open to change Rapid change process Fun and exciting products Change mentor halfway through the internship Never got opportunity to drive any of the products 7Denny Kramer, Intern Presentation Summer 2015 Likes
- 8. 8 Lesson’s Learned/ Future Plans Denny Kramer, Intern Presentation Summer 2015 Lean Principles: Better understanding of Lean Manufacturing vernacular Utilizing Plan, Do, Check, Act – Continuous Improvement process Identifying if issues are really problems – knowing the standard to measure against Need measurables when dealing with problems – can go back and see if there is an improvement Utilizing different problem solving methods – A3, 5 why’s, fishbone diagrams Data gives direction Future Plans: 3 semesters left at Iowa State University 1 summer internship left – Design Engineering oriented
- 9. Questions? 9 Thanks Polaris for the opportunity! Denny Kramer, Intern Presentation Summer 2015
Editor's Notes
- #4: Results from Kaizen that we came up with: new paint plugs, teflon coated nuts, changes in fixtures in weld – weld spatter in them Tooling = got to meet more people in the dept and learned how to go about getting tooling created in mantenaince New Product Implementation
- #5: Tools used Implementation
- #6: Follow up - Helped operator in any way I could so they would not fall behind on the line as changes were being made.