Your Partner in Precision Gearing, Machining and Assembly
Transformation of Existing Operations…
Lean Project 1
Manufacturing Infrastructure Transformation
Initial State Benefits of Transformation
• Unorganized work environment. • Increase in production flow efficiency by 30%.
• Safety barriers not present. • Safe and Lean work environment: 100%
increase in safety.
• Organized work flow.
• Valuable floor space gained.
Initial State
16,320 sq/ft manufacturing
facility prior to transformation
Infrastructure and Safety
Current State
Implementation:
Floor organization and safety
Areas:
Event #1: Snack Area
Project Scope and Structure:
Event #2: Lunch Area
Lean and Environment Implementation
Event #3: Calibration Area
Event #4: West Walk Way
Event #5: Shipping Shelves
Event #6: Inspection Lab
Event #7: East Walk way
Event #8: Parts Washer Area
Event #9: Document Area
Event #10: Conventional Area
Event #11: Record Keeping Area
Event #12: Growth Space Drive way
Total Cost of Transformation $ 800
Total Time Invested: 10 hours
Event #13: Shipping and Receiving Area
Total Square Footage: 10,000
Date of Completion: June 25, 2008
Infrastructure and Safety
Current State
Organized work flow Valuable floor space gained
Safe and lean work environment
Clearly marked aisles
Infrastructure and Safety
Lean Project 2
Quality Department: Inspection Measuring Equipment
Initial State Benefits of Transformation
• Unorganized tool retrieval. • 100 % increase in tool accessibility.
• Insufficient work space. • 50 % increase in retrievable efficiency.
• 75% increase in work space capacity.
Initial State
Quality Department
Current State
Measurement inspection equipment is stored in one vertical
cabinet and each drawer and internal slot is identified.
Quality Department
Current State
Reorganized Inspection Cabinet. All measuring
tools will now be readily available for use.
Quality Department
Zeiss Prismo Navigator
Gear Analyzer
• Scanning Technology and Accuracy
- Zeiss Vast Gold Probe Head with Rotary Table
is calibrated up to .5 micron accuracy range.
• Gear Analyzing Software
- Gear Pro 3.6
- Calypso 4.1
• Gear Configuration Capabilities
- The Zeiss Prismo can support the following
gear configurations: Spiral Bevel, Gleason Bevel
Straights, Internal and External Spur Gears,
Worm Gears, Helical Gears, and Internal and
External Splines.
Total Cost of Transformation: $ 283,500
Total Time Invested: 150 hours
Total Square Footage: 572
Date of Completion: June, 2010 Quality Department
Lean Project 3
Tool Room
Initial State Benefits of Transformation
• Tools not readily available for retrieval. • Tooling inventory is now accessible and readily
• Poor house keeping. available through our computerized database.
• Hard copy inventory system. • Start up times were reduced by up to 50 %.
• 100% increase in time efficiency improvement.
• 50% increase in valuable floor space gained.
Initial State
Tool Room
Current State
•
Tool Room
Current State
Total Cost of Transformation: $ 9,000
Total Time Invested: 40 hours
Total Square Footage: 320
Date of Completion: Oct. 2009
Tool Room
Lean Project 4
Shipping & Receiving
Initial State Benefit of Transformation
• Disorganized working environment. • 50 % increase in work space capacity.
• Insufficient product flow. • 50 % increase in product flow efficiency.
• Insufficient work space. • 50 % decrease in shipping materials.
Initial State
Shipping & Receiving Department
Initial State
DISASTER !!!
Shipping & Receiving Department
Current State
Estimated Cost of Transformation: $ 3,000
Estimated Time Invested: 16 hours
Total Square Footage: 700
Estimated Date of Completion: Feb. 2010
Shipping & Receiving Department
Future Lean Improvements
Date of Completion: August 2010
Project: Shipping & Receiving Department Make-Over
Process Improvement
Summary:
We have targeted this department to improve product flow and
organize for efficiency. Our goal is to identify shipping from
receiving.
Details:
1. Conveyor roller system to help the flow on the shipping end.
2. Two new flat screens mounted on each wall to increase work
...space.
Reorganized existing state
3. Bar code system to fulfill shipping requirements. for future conveyor system
4. Two new 8x3 foot work benches. These work benches will
…increase work space for the identification process.
5. Two new chrome racks for shipping materials.
6. Increase storage space with two new shelves.
Shipping & Receiving Department
Lean Project 5
Deburring Department
Initial State Benefits of Transformation
• Unorganized work environment. •12x20 built in air conditioned room.
• Poor air quality. • 85 % increase in safety (Air Quality).
• Insufficient lighting. • 80 % increase in vacuum efficiency.
• Limited vacuum efficiency. • 75 % increase in process lighting.
• 50 % increase in work space capacity.
• 50 % increase in deburring machines.
Initial State
Deburring Department
Current State
5 Horsepower Vacuum
Total Cost of Transformation: $ 29,524.98
Total Time Invested: 12 months
Total Square Footage: 240
Date of Completion: January, 2010 Deburring Department
Lean Project 6
Engineering and Production Management Offices
Initial State Benefits of Transformation
• Small 10x10 offices. • Management is now able to conduct
• Insufficient facilities for internal in office meetings.
conferences. • Total facility capacity increased by 800 sq/ft.
• Insufficient facilities for added resources. • 288 sq/ft now available for additional resources.
Initial State
New office location
prior to construction
Engineering and Production Management
Current State
Two 10x20 offices to
support engineering and
production management
Total Cost of Transformation: $ 20,000
Total Time Invested: 80 hours
Total Square Footage: 810
Date of Completion: Oct. 2009
Engineering and Production Management
Lean Project 7
Conference Room
Initial State Benefits of Transformation
• Hardcopy communication system. • State of the art audio/visual ability.
• Outdated technology. • Paperless communication system.
• Insufficient communication. • 75 % communications improvement.
• Increase in employee training and quality
awareness.
Initial State
Conference Room
Current State
Wireless capabilities
Weekly management
meetings conducted in
the conference room
Total Cost of Transformation: $ 2,000
Total Time Invested: 16 hours
Total Square Footage: 198
Date of Completion: Aug. 2009
Conference Room
Lean Project 8
Assembly Department
Initial State Benefits of Transformation
• Limited assembly area: 10x12 ft. • Increased work capacity by 50%.
• Unorganized assembly area. • Two 3x8 ft work benches.
• No confined structure over assembly area. • Work bench assembly increased by 60%.
• Overhead lighting improved by 80%.
• Temperature controlled environment.
• Additional airlines for pneumatics.
Initial State
Assembly Department
Current State
Assembly Department
• One 12x20 built in room.
• AC and airline jacks for new
assembly area.
• Lighting.
• Fully equipped work benches.
• Engineered as a clean room
environment.
Estimated Cost of Transformation: $ 25,000
Estimated Time Invested: 85 hours
Total Square Footage: 240
Date of Completion: Dec. 2009 - Jan. 2010
2010
Improvements
Shaping Department
Fellows RC 20-4 Gear Shaper
Capacity: 20”Diameter x 4” stroke.
Purpose: Support capacity and
capture the large product market.
Cost of Transformation: $ 270,000
Estimated Time Invested: 55 hours
Total Square Footage: 500
Date of Completion: 1st Quarter 2010
Additional Resources
2nd Qtr
Quality department
Chief inspector (CMM) programmer / operator
Experience: 15 years CMM programming,10 years mechanical,5 years Quality engineering
and 5 years manufacturing engineering.
Purpose: support quality
Quality department
1 additional mechanical inspector
Experience: 20 years mechanical, 10 years CMM and 5 years calibration.
Engineering department
1 additional Mechanical Engineer
Experience: 16 years Mechanical Engineering (BS degree): CAD, Solid works, Master cam.
Purpose: Support quality planning and production schedule and engineering
3rd Qtr,
Grinding department
1 additional grinding operator.
Purpose: Support production schedule.
4th Qtr
Gear department
2 additional gear manufacturing operators.
Purpose: Support production schedule.
Production department
Hired an Assistant Production Manager
Experience: 9 years Production Team leader: lean mfg, SAP systems, real time problem
resolution, process analysis and Kaizen leader.
Purpose: Support production schedule and streamline our manufacturing processes.
Future Lean Project 9
Parts Washing Department
Initial State Benefits of Future Transformation
• Physical lifting process. • Hoist and Gantry electronic system.
• Load capacity per basket 40lbs max. • Load capacity increased by 60%.
• Limited production flow. • 60% increase in production.
• 100% safety improvement.
Future Lean Improvements
Initial State
Parts Washing Department
Here is a sketch of the Gantry and
Future Lean Improvements
Hoist system and two work
benches . This transformation will
increase productivity, efficiency,
and safety.
Electric Panel Clearance
All three tanks will be shifted east about 12”
eliminating any obstructions.
Gantry and Hoist System
This addition will allow employees to
maneuver parts from tank to tank in a much
more efficient manner. The gantry and hoist
system also eliminates any physical injuries.
Work Benches
The benches will provide employees with
room to temporarily store parts that need to
be or have been washed. The benches will be
24” x 36” x 30” in dimension.
Estimated Cost of Transformation: $ 2,685
Production Flow Estimated Time Invested: 40 hours
This future project will increase productivity Total Square Footage: 320
and efficiency in the Washing Department. Estimated Date of Completion: November. 2010
Parts Washing Department
“Gear Technology is dedicated to continuous lean
improvements and the transformation of existing
operations. Our goal as a corporation is to far exceed
all customer requirements and expectations.”
Tom Marino
President
Your Partner in Precision Gearing, Machining and Assembly
For further information please visit our website.
www.gear-tech.com