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Precision Parts Projects

Precision Parts

PROJECT DESCRIPTION

The company produces high precision parts in the Electrical engineering and communication industry. Using multi spindle turning and milling machines the setup times were long and the management wanted to reduce them drastically to improve productivity.

PROJECT PLANNING and EXECUTION

The company had a PDA (production data acquisition) into which the machine production and down time was filled manually. Setups of machines were done by special technicians based on their experience and knowledge.
First the setup process needed to improve by standardizing the process by using Work Instructions and standardized setup sheets. Second the data had to be extracted out of the SAP system and analyzed. Third a PDA system which did read the information directly out of the machine was installed.
Analyze of the data revealed that the setups were interrupted to repair machines.

Target

Target:

Reduction of Change Over Time

Toolbox

Tool Box:

PDA (production data acquisition) analyze, 5S, SMED, Communication, Team Work

Achievement

Achievements:

Reduction of Change Over Time by 15%,
Reestablishing of Maintenance


PROJECT DESCRIPTION

A Hard Metal production company got 24 new machines and had to optimize the layout to increase capacity. The layout was arranged to process cells and not to product lines. The company is producing 2 kinds of hard metal products which share operations at the beginning of the process flow but split to different machining processes after sintering.

PROJECT PLANNING and EXECUTION

The first step was to understand the process flow and volumes produced. Here the value of the products had to be considered, because the products did not only different in the size but also in the volume.
A current flow chart and P-Q Analyze were made and based on the result the new layout was created, rearranging the cell production to a mixed cell-line production.

Target

Target:

Optimize Plant Layout and gain space for new machines
Toolbox

Tool Box:

Flow Chart / Material and Operator movements
P-Q Analyze
Line Balancing
One-Piece-Flow Principles
Cell Layout
Ergonomics

Achievement

Achievements:

Material movement reduction 44%
Space utilization 25% of former used space incl. adding of 20 new machines
Request for layout design of a new production area

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