A3 Report (Lean Manufacturing template for PDCA), Applied to a project to reduce line down  due to lack of returnable boxes. ... Relatório em formato A3 (Template para o PDCA usado no Lean Manufacturing), aplicado a um projeto de redução de paradas de linha devido falta de embalagens vai-e-vem.

1. 1A. Opportunity: Elimination of Planning Downtime
A3 Report
Team Member
Names:
Site/Plant: Manaus
Date:22/08/2012
Group/Workcell/Site: STB
Leader: Thiego Silva
Annual Savings (US$):
1B. CLARIFY THE PROBLEM:
Rodrigo Marques
Downtime IM / FA
Root Causes
Problem Identification:
High
Where:
IM/FA
Wk 25 ~ Wk 28
How much:
-100% of planning
Downtime is related
to Lack of available
package in the
process.
What:
When:
2. BREAKDOWN THE PROBLEM:
Mentor: Thiego Silva
5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES:
Key Metric to Impact:
High Downtime:
IM / FA
Nattyer Nunes
Selected Countermeasure
Who
Finish
IC Team
WK 1229
WK 1229
Thiego Silva
WK 1229
WK 1229
Providing area for packaging in shelves
15%
There is no
standardization at
location of packages by
size and model.
Separation and standardization of packages location
according to the type
Visual identification of each location for packages
Rodrigo Marques
Data collection – After improvement
Waste(s) Identified
Target
7. EVALUATE RESULTS:
Transportation:
WK 1229
WK 1229
Nattyer Nunes
Planning Downtime
Eliminated
WK 1229
Before
WK 1229
A fter
Inventory:
Savings
Motion:
Waiting:
MVA – Material Value Added
per unit
US$ 6 / unit
MVA / Hour (MVA x Rate)
X
US$ 1422 / h
- 15% of Average
Downtime IM/FA is
related to Planning.
Overproduction:
Defects
Plannig Downtime
5 Hours / Week
- Average Downtime
is 5 hours per week.
Skills Unused
Total Saving/WK
US$ 7110/ Week
Total Saving/Month
US$ 28440 / Month
Over processing
3. SET A TARGET (The challenge):
8. STANDARDIZE:
Eliminate Planning Downtime from 5 Hours per Week to 0 Hours per Week by July 2012.
4. ANALYZE THE ROOT CAUSE:
Environment
- Lack of organization of the location of packages
- The location of packages is not standardized
Planning
Downtime: Lack
of available
package
- Operator loses time when looking for packages
- Employees not trained about how organize the place of package
Method
Means of Standardization:
Standard Work
-Why planning Downtime?
Due lack of available package in the
process
-Why?
Because the packages were not available
when the process was requested.
-Why?
Because operator loses time looking for
packages
-Why?
Due lack of organization of the packages
-Why?
There is no standardization at location of
packages by size and model.
Visual Aids
Global Document /Procedures
Training
Other
X
Process Audits:
LPA
TPM Checklist
5S Audit
X
Other
Next challenge:
- Eliminate buffer and other wastes that can be solved by Planning Team.
Sharing with others:
- Share this project with production leaders and stock area employees.
Lessons Learned:
Visual Management is an important tool. It makes problems visible.
Form #: F-108 - Revision Date: 02/17/2012