Key Project Objectives

• To make change processes more flexible with the aim of reducing the plant's lead time in its strategic product line.
• Train staff on continuous improvement concepts & Involve staff in every stage of the re-engineering process of change
• Introduce the concepts of 5S, Ergonomics, SMED and Parallel Work
• Create a reporting program that allows you to store and monitor the results.
• Form an internal team for the management & execution of SMED projects

Methodology & Action Summary in 7 Steps

Step 1: Educate to change / open minds

Step 2: Classify / Eliminate variability

2.1 Define the Key Products

Reduction from 25 to 20 Key Products by eliminating products with low or zero production levels in 2012.

2.2 Create Change Class Matrix

Step 3: Define the Starting Point: Where are we?

Step 4: Improve the work environment

Step 5: Democratic Re-Engineering

Step 6: Monitor & Capitalize on Improvements

Step 7: Technical & Functional Improvements

1. Elimination of the need for “Sprays” & Independence with Maintenance
2. Mechanical Improvement of the Villars Machine
3. Electrical Upgrade of the Villars Machine

Lean Change C2 Observations: White ->

1. Creation of a dust deviation control program & Independence with production managers
2. Control of those in charge through Reporting
3. Control of those in charge through supervision of external tasks

Lean Change C2 Observations: White->White with Spray: 54 minutes

White with Spray

Process Re-Engineering Summary

Number of optimized processes

• 66% of the changes observed, defined and optimized
• 34% of the improved changes

• Process Re-Engineering Summary

  	Output1	Output2	Output3
  C1	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change
  C2	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change
  C3	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change
  C4	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change
  C5	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change
  C6	Previous External Tasks	Work sequence with 2 PAX	External tasks post-change

  Process dossier

Summary of Actions Taken & Pending

5S Actions: Order / Cleanliness / Safety

7S Actions: Ergonomics / Displacements

Organizational Actions

• Creation of the process dossier
• Operator training
• Definition of external work
• Definition of Objectives

Functional Actions

• Creation of the powder weight program
• Training of those in charge
• Creation of communication & reporting panels

Pending points

Using the powder weight program:

Control of actual weight deviation vs. target / Tray weight deviation / Digital adjustment

Outsourcing the assistant's work:

Having an additional easel for the start of production

Project Results

Analysis of the initial results regarding the implementation period

Coating Trends 2012 1