Kaizen Presentation Js847 Slideshow Sept 2011
- 1. Outside Inventory and Material Storage Improvement Date: April 27, 2011 to June 18, 2011 Area: Fridley Yard, East Side of Manufacturing Plant & Tech Center 5S / Material Reduction
- 2. PROJECT: Identified and removed excess & obsolete materials and possible safety hazards, as well as consolidate current inventory away from employee parking (parking lots 4 & 6); Identified non-inventory scrap materials and safely removed them from the property; Developed a location ID system for outside inventory (i.e. Line Mapping Grid); Identified new material and inventory yard storage locations for future outside inventory. Save Cummins money by recycling scrap material.
- 3. OUTSIDE INVENTORY AND MATERIAL STORAGE IMPROVEMENT KAIZEN TEAM Team Members (Front Row) Andrew Jenson, Tom Gerrety, Trish Pike, Sallie Malmstrom (Team Lead), Jim Callander, (Back Row) Anita Costello, Gayle Gruber, Jacob Kriesel, Ryan Paulson, Greg Schrader. (Not Shown) Jim January, Bart Bashynski, Sheila Minske, Ron Rahier, Patrick Eng, Jennifer Schumann, Lynn Keate, Niki Yuds, Larry Hokenson, Al Stephens, Paolo Caffari, Brian Walton, Pete Awsumb.
- 4. TEAM’S GOALS: Make Cummins a safe work environment for everyone by removing potential safety hazards; Reclaim valuable space by removing scrap inventory; Reclaim areas for their intended purpose (i.e. area that is designated as employee parking). PARKING LOT #4 SPACE INCREASED BY 68% AFTER SCRAP WAS REMOVED. Parking Lot #4 – before... and after.
- 5. Scrap locations identified in the yard.
- 6. WHAT THE TEAM SET OUT TO DO: Tech Center/ Engineering: Identify obsolete prototype equipment for removal behind the building and in the yard. LNE 22/ T-REX: Identify obsolete and NCMR trailers and tanks in parking lot #6 for removal or resale. BEAR: Identify obsolete prototype equipment for removal behind the HHTF building and in the yard. THOR 1 & 2: Identify obsolete equipment for removal behind the manufacturing building and in parking lot #4. LNE 26/27: Identify obsolete prototype equipment for removal from parking lot #4 and in the yard. PAC-NET/ STEEL WASTE: Identify damaged wood packaging and steel skids as well as obsolete equipment (i.e. radiators) for removal from various yard locations.
- 7. WHAT THE TEAM ACHIEVED 1. RECLAIM DESIGNATED AREAS Kaizen Results Tracker 2. REMOVE SAFETY HAZARDS 3. SAVE VALUABLE YARD SPACE June 18, 2011 Before After Total Space Area % YARD AREA Kaizen Kaizen Savings Increase Lot #4 Outside Inventory 24,600 sq. ft. 7,825 sq. ft. 16,775 sq. ft. 68% Lot #6 Outside Inventory 11,500 sq. ft. 7,100 sq. ft. 4,400 sq. ft. 38% By H.H.T.F. Fence 9,750 sq. ft. 5,000 sq. ft. 4,750 sq. ft. 49% By Plant Doors #21A / 22 8,450 sq. ft. 6,630 sq. ft. 1,820 sq. ft. 22% Behind Tech Center 20,650 sq. ft. 2,800 sq. ft. 17,850 sq. ft. 86% By Hazardous Materials Building 6,800 sq. ft. 5,000 sq. ft. 1,800 sq. ft. 26% By Murphy Warehouse Door #198 2,600 sq. ft. 2,600 sq. ft. 0 sq. ft. 0% By JP-8 Tank 3,000 sq. ft. 0 sq. ft. 3,000 sq. ft. 100% GRAND TOTAL (sq. ft.) 87,350 36,955 50,395 58% OUTSIDE INVENTORY SPACE USED TOTAL AMOUNTED AFTER KAIZEN SAVED BY RECYCLING SCRAPED MATERIAL: $5622.51 BEFORE KAIZEN
- 8. KAIZEN TEAM TASK LIST Status Kaizen Task Tracker Date Issue Priority Owner COMPLETE DOC. Project Assigned IDENTIFY DEPARTMENT REPRESENTATIVES FOR TEAM 04/27/11 High JS847 √ √ √ IDENTIFY OUTSIDE INVENTORY SCRAP LOCATIONS 04/27/11 High JS847 √ √ √ LIST ALL OUTSIDE INVENTORY AS SCRAP OR NOT 04/27/11 High JS847 √ √ √ IDENTIFY SCRAP OWNERSHIP; DEPTS. VERIFY ITEMS 04/27/11 High JS847 √ √ √ DEVELOP A LINE MAP GRID FOR OUTSIDE INVENTORY 04/27/11 High JS847 √ √ √ IDENTIFY NEW OUTSIDE INVENTORY LOCATIONS 04/27/11 High JS847 √ √ √ PUT "ORANGE FLAGS" ON SCRAP ITEMS 06/06/11 Med JS847 √ √ PUT "YELLOW FLAGS" ON ITEMS FOR RELOCATION 06/06/11 Med JS847 √ √ IDENTIFY SCRAP TANKS WITH FUEL; DRAIN THEM 06/06/11 High CI546 √ √ LOCATE FLAT BED TRUCKS FOR SCRAP LOADING 06/06/11 Med CI546 √ √ LOCATE TEAM MEMBERS FOR HELP WITH EVENT 06/13/11 Med GQ660 √ √ LOCATE EQUIPMENT FOR USE DURING EVENT 06/13/11 Med GQ660 √ √ COMPLETE EVENT ON SATURDAY, JUNE 18, 2011 06/18/11 High JS847 √ √ WRITE UP "LESSONS LEARNED" FOR JIM JANUARY 06/22/11 Low JS847 √ √ √ RECLAIMED 49% MORE AREA BEHIND H.H.T.F. BUILDING AFTER SCRAP REMOVED
- 9. NEXT STEPS: Reduce wood packaging waste from reoccurring through better Bill of Material management; Reduce safety stock quantity and/or relocate it in a warehouse to keep from being weather-damaged; Provide equipment and trailer racking for better consolidation of yard space; Appoint an outside inventory yard manager to oversee the oversized inventory material storage. RECLAIMED 41% MORE PARKING AREA IN LOTS #4 AND #6 WHEN SCRAP WAS REMOVED.