Non Filter Line Kaizen

1
Non-Filter Kaizen Sabritec
2
Kaizen Team
Eric Cooper Richard Nagel Esther Jimenez

• Nena Delval
• Brian Takushi
• Rosa Elvira
• Alex Simampo
• Lourdes Posada

Lourdes
3
The Non Filter Line (NFL) Team
Lourdes
4
Kaizen Goals

• Develop Line Design calculations for the Non
  Filter Connectors
• Develop conceptual drawings for layouts
• Place the area into Mixed Model cells
• Develop a list of tools/equipment required for
  each cell per operation
• Begin the kanban strategy for Non Filter

Lourdes
5
Process Relationship Diagrams
Short Cell
Assy
Package
Eol
Vis. Insp.
Medium Cell
Assy
Assy 2
Pot
Bond
Elec Test
Package
Eol
Mark
Long Cell
Coax Cable
Press
Solder
Mark
Solder
Solder
Assy
Press 2
PCB
Insert Assy
Elec. Test
Pack
Assy 2
Eol
Cable
Nena
6
Takt Time
Rate or Beat Determines how often the line
produces a product Hours Shifts / Demand Short
Cell Takt 5.0 min Medium Cell Takt 10.0
Min Long Cell Takt 7 min
Nena
7
Process Map- Times
Nena
8
Line Design
Short Cell
Op 10
Op 20
Visual Insp. Assy
Assy Pack
Medium Cell
Op 10
Op 20
Op 30
Assy Pack
Visual Insp. Assy
Bond/Pot
Eric
9
Line Design
Long Cell
Op 40
Op 10
Op 20
Op 30
Visual Insp. Assy Form
Assy Insert
Assy
Assy
Op 80
Op 50
Op 60
Op 70
Solder Press Crimp
Water Test
Bond/Pot
Pack
Eric
10
Tooling Requirements
Short Cell
Op 20
Op 10
Arbor Press Microscope Lamp Std
Tools Vials Bags Sealer Labels Cartons
Microscope Lamp Air Std. Tools Arbor Press
Elvira
11
Tooling Requirements
Medium Cell
Op 10
Op 20
Op 30
Large Arbor Press Arbor Press Hand Tools Std
Tools Vials Bags Sealer Labels Cartons Foam
Microscope Lamp Air Std. Tools
Arbor Press Microscope Lamp Bonding Disp Bonding
Gun Mixing Plate Std Tools Small Oven
Esther
12
Tooling Requirements
Long Cell
Op 30
Op 40
Op 20
Op 10
Arbor Press (2) Hand Tools Std Tools Lamp Air
Arbor Press Std Tools Lamp Air
Microscope Lamp Air Std. Tools Hand Tools Arbor
Press
Solder Paste Solder Disp. Arbor Press Std.
Tools Lamp
Richard
13
Tooling Requirements
Long Cell
Op 70
Op 80
Op 60
Op 50
Solder Irons Microscope Resistance Solder Crimp
Press Heat Gun Hand Tools Std. Tools Lamp
Arbor Press Std Tools Bags Sealer Labels Cartons F
oam
Bonding Disp. Bonding Gun Mixing Plate Std.
Tools Small Oven Arbor Press Lamp Microscope
Water Test Mach. Air Hand Tools
Richard
14
Operational Definition
What material goes at which operation? What work
is done at an operation? Balance the work across
all of the operations One of the most important
pieces of implementing the Flow Line
Richard
15
Layout Options
Option A
Disadvantages If kanban not established, Feeder
process will fail Kits staged throughout area
Advantages Tin dip separate from cell for
safety reason. Q.A. visible and located on
assembly Floor One feeder supports 2
lines Support team members located within Cell
16
Layout Options
Option B
Disadvantages If kanban not established, Feeder
process will fail Kits staged throughout
area Loud contact machine moved into area
Advantages Ovens located in each cell Tinning
near the long cell One feeder supports 2 lines-
near the Medium and long cell Marking near both
cells as required
17
Layout Options
Option C
Advantages Kits located in each cell Feeder line
attached to main line Support members located in
each area Smooth flow design Each line has the
equipment to perform all operations- i.e. ovens
Disadvantages Loud contact machine moved into
area
18
Next Steps

• Complete Operational Definition
• Decide on what parts need to be Kanbaned
• Complete Filter Line Design- develop an overall
  floor layout
• Write SOEs and balance the work
• Take the Line Live
• Visit Tecom

Alex
19
Next Kaizen

• Feb 1-4, 2005 Filter Connector Line

Alex
20
Current Operations
Kits Issued from Stock Room Staged in multiple
locations No visual method of identifying kit
issues Inadequate communication tools between
production and planning
Alex
21
Proposed Solution
Centralize kit area within product line Color
Code kits for disposition Visual system will
improve communication between the floor
and Support teams- i.e. planners, engineers, etc.
Alex
22
Kit Color Codes
Complete Kits
Short Kits
Technical/Contract Issues Kits
Short Tooling Kits
Alex