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This
article tells how Kaizen Events
(Blitz) successfullyy improved workflow, productivity and quality
for a manufacturer of industrial heaters.
Cartridge
Heater
-
Welded
end seal.
-
Mica.
-
Stainless
steel sheath
-
Element
wire
-
Magnesium
oxide packing.
-
Ceramic
element support.
-
Ceramic
cap.
-
Teflon
insulated leads
Strip
Heater
-
Post
Terminals.
-
Mica
Insulator.
-
Resistance
Ribbon Wire.
-
Mica
Element Support.
-
Rust
Resistant Steel Sheath.
Background
Pele
Products (not the firm's real name) manufactures a wide variety
of electric heaters. These heaters go into dishwashers, hot tubs and
many consumer and industrial appliances or equipment.
Two
of the many different types of heater are shown above. Each
type of heater has many variations in voltage and wattage
as well as in dimensions and physical features. There are tens of
thousands of possible permutations. Because of the almost infinite
variety, most heaters are made to order.
The
plant was originally arranged in a functional layout
which required each order to travel to several departments. Normal
lead time was about 60 days and even expedited orders
required 15 days. Scheduling was very
complex and generally considered ineffective.
The
blitz approach was used to implement six workcells.
Preparation
The
product and process complexity required considerable analysis and
preparation in advance of the actual blitz. The products were
grouped into families with similar characteristics and enough volume
to justify a workcell. Two of these families were the product groups
shown above. A separate cell prepared ceramic cores and wound them
for the other cells that used these cores. |
The
Kaizen Event
The
actual detail design and rearrangement was done in several sessions.
Each session required about one week. Maintenance personnel worked
late shifts to rearrange equipment. Production was at normal volume
within two days.
The
layout for the Cartridge Cell and Strip Cell is below.
Results
The
most important result was lead time reduction. An average
order now requires 5-10 days and expedited orders require three
days. This is a great convenience to Pele's customers and an
important competitive advantage for Pele.
In
addition, inventory dropped significantly, the factory was more
orderly, quality improved and productivity increased.
Other
Articles
Is
The Kaizen Blitz Right For You?
(Article)
Kaizen
Blitz Overdose (Article)
Kaizen
& One Piece Flow (Article)
Rationalized
Workcell Design (Article)
Strategos
Programs
Workcell
Design Seminar
Workcell
Blitz
Setup
Blitz
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