LEAN ENTERPRISE AND CONTINUOUS IMPROVEMENT ENGINEERING
- 1. Slide Design© Duarte, Inc. 2014 LEAN ENTERPRISE AND CONTINUOUS IMPROVEMENT ENGINEERING Thinking Lean From Design To Production MARK KREITINGER
- 2. Slide Design© Duarte, Inc. 2014 Lean and Continuous Improvement Engineering +Apply Six Sigma and Lean Tools from design to production +Improve processes and product development +Investigate and troubleshoot production difficulties +Identify and reduce waste ImproveThink Lean Troubleshoot Eliminate 02 03 0401
- 3. Slide Design© Duarte, Inc. 2014© Duarte, Inc. 2014 THINK LEAN 01
- 4. Slide Design© Duarte, Inc. 2014 Think Lean Throughout the product life cycle, from design to production At Munro and Associates, a study of a client’s product showed that complying with regulations had caused ineffective fixes Developed a solution for the client that allowed to redesign their product to meet current and new regulations and reduce parts The proposed redesign represented $8M in savings to the client by using a new design. A study of the Cummins generator, and the competitor’s product revealed significant design differences Demonstrated a way to reduce cost per unit by reducing number of parts, using analytics from Design Profit Software The information from comparative analysis positioned the company’s product to better compete in the market. Polaris acquired Timbersled, a snowmobile kit manufacturer whose product had high production costs Conducted a study of one part of the product and analyzed for cost reduction and part reduction opportunities by using Design Profit The result of the study demonstrated savings of $140K. With further analysis, there is potential for exponential savings. Work area layout and engine tear-down procedures at Polaris, offered opportunities for improvement Conducted Kaizen events with team members across multiple functional groups As a result of the events, we were able to implement an improved work area layout and created documentation for the tear-down procedure
- 5. Slide Design© Duarte, Inc. 2014© Duarte, Inc. 2014 IMPROVE 02
- 6. Slide Design© Duarte, Inc. 2014 Improve Seek opportunities to improve processes using changes to product specifications and test to verify results Collection boxes at the Post Office made handling mail cumbersome Suggested an improvement to mail box design in order to make the process of handling mail more efficient Obtained a degree in Mechanical Engineering, since it was the Post Office’s requirement to redesign mail collection boxes TMI, a casework and countertop manufacturing company needed to improve their assembly process Gathered over 100 ideas by performing tasks at all work and assembly stations. Project revealed potential risks to worker safety. To solve it, designed an automatic stop to increase efficiency and prevent injury At the metal paint department at Polaris, their paint line was setup in a limited space and had to handle loading and unloading of parts, which caused significant downtime Designed a new layout and moved loading and unloading offline and in a different location Material movement was improved and the need for downtime was eliminated At Cirrus Design, their aircraft build rate was not meeting their goal of two per day Analyzed workflow and identified the need to add one more ply cutter The addition of another ply cutter allowed to reach the goal of building two aircraft per day
- 7. Slide Design© Duarte, Inc. 2014© Duarte, Inc. 2014 TROUBLESHOOT 03
- 8. Slide Design© Duarte, Inc. 2014 Troubleshoot Seek opportunities to identify, troubleshoot and correct production difficulties The metal paint department at Polaris had an issue with an inadequate oven stop on the conveyor line in which parts had to cure for a certain amount of time Redesigned the stop to work at a 45 degree angle, opposed to working completely horizontally. This resolved the issue that was causing the stop to fail. The solution was effective, even though the supplier of the conveyor line had communicated to Polaris that it could not be done
- 9. Slide Design© Duarte, Inc. 2014© Duarte, Inc. 2014 ELIMINATE 04
- 10. Slide Design© Duarte, Inc. 2014 Eliminate Use analysis to identify opportunities to eliminate waste throughout the organization Eclipse Aviation, a startup company, was trying to obtain type certification for their Eclipse 500 aircraft Conducted a company- wide process audit After implementing the process and training the organization, Eclipse Aviation obtained type certification for the Eclipse 500 six months ahead of schedule Audit revealed substantial gaps in communication between functional groups. There was a breakdown in the hand-off process from group to group. Discovered that most employees were not aware of how to establish a relationship with the FAA for aircraft type certification Wrote a procedure to eliminate gaps, which caused waste of time and resources Documented the procedure manually, before automating it using SAP Obtained buy-in from senior leadership and trained 250+ employees in how to implement it
- 11. Slide Design© Duarte, Inc. 2014 MARK KREITINGER Over 20 years of comprehensive experience in multiple industries such as manufacturing, aviation, automotive, emission solutions, power generation and sports and utility vehicles. Lean Engineering and Continuous Improvement Professional Highly knowledgeable in lean enterprise processes, focused on cost reduction and weight reduction practices applied in end- to-end product design. An innovative individual with a proven 7-step process to assist organizations and facilitate the intersection between engineering and manufacturing. 608.609.0032 mark.kreitinger@gmail.com Linkedin.com/in/markkreitinger Image source www.icons8.com