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Impact Report

Impact Report. Project: Correct gas flow on one welding machine in Rear Frame Areas. Problem Description: Found missing Gas Flow Restrictors causing excessive shielding gas consumption. After. Before. I. Restrictor Installed. No Restrictor Installed.

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Impact Report

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  1. Impact Report Project: Correct gas flow on one welding machine in Rear Frame Areas. Problem Description:Found missing Gas Flow Restrictors causing excessive shielding gas consumption. After Before I Restrictor Installed No Restrictor Installed Solution: Installed Gas Flow Restrictors. Benefits:$1,661.00 annualized savings. Improve product quality. Sustainability:Process Audits/ Maintenance training.

  2. Impact Report • Project: Duraplate Safety Improvement – Push Blocks. • Problem Description: Associates were using utility knives to grab hold of the plastic sheet to feed the process creating high potential for serious injury. • Solution: Utilize woodworking technology “push blocks” to improve safety. • Benefits: For $4.99, we will lower risk of injury and improve ergonomics. • Sustainability: Update Associate PP&E.

  3. Impact Report Project: Create a temporary punching cell for Mains & Secondaries. Driving Issue:Press will be down for several weeks for repairs, backup process is too slow to continue for this long of time period. Solution:Use existing tooling in another press which happens to be available, move existing in-feed table, and build a temporary out-feed roller table. After Before Benefits:Allowed Wabash to operate at normal production rates, without added cost of using outside sources to balance the volume needs. Sustainability:This was a temporary cell and will be disassembled after the normal press is repaired in 4 to 6 weeks.

  4. Impact Report Project: Line 5 53’ Unit Plan and Preparation Problem Description:Line 5 has been geared toward being a Pup only line. Now there are 53’ units in the schedule. Lengthened all cart tracks Lift to prevent line cart damage trailer stop for associate quick ref. Added conveyor run to prevent sides from sliding to the floor Added new cart and floor drill from Line 3 to prevent possible bottle neck issues Solution:Through planning and prep by Tony Hill and I we were able to get all of the necessary changes scheduled and made prior to the run. Benefits:We have made or exceeded scheduled production all but two days out of the 17 that we have been running; neither at the beginning of the run. This equates into a savings on the anticipated loss of $16,953. (assumption = 8 missed cycles during first three days of prod.) Sustainability:Line improvements have been made and must be in place to run.

  5. Impact Report Project: Line 5 Impact gun change Problem Description:The current impact guns being used weigh approximately 6 pounds each. This has created several trips to medical due to hand/wrist strains. New style impact 3.24 pounds Old style impacts 6 pounds Solution:Purchased a much lighter impact from Ingersoll-Rand that weighs almost half of the weight of the current impacts being used. Benefits:The associates are much less likely to develop hand/wrist injuries from the new guns. The soft savings from the trips to medical = $3,200.00 Sustainability:All of the old impacts have been collected.

  6. Impact Report Project: Line 5 Intercostal welder elimination Problem Description:The Intercostal welders have to lift their hoods an excessive amount to see the product and the quality of the welds. New style hood that allows the associate to keep their eye on their job. Old style regular hood that requires lifting to see the product Solution:Purchased a Speedglas hood that allows the associate to keep their hood down at all times. Benefits:The process use to take two welders to complete all of the welding for the required cycle time. Now we can do the same amount of work with one associate. Savings = $25,000 annually in associate salary. Sustainability:Once the hood is issued it becomes the responsibility of the associate.

  7. Impact Report Project: Correct gas flow on one welding machine on Line 5 intercostal jig. Problem Description:Found drilled out Gas Flow Restrictors causing excessive shielding gas consumption. After Before I New Restrictor Installed Restrictors drilled out Solution: Installed new Gas Flow Restrictors. Benefits:$2,014.00 annualized savings. Improve product quality. Sustainability:Process Audits/ Maintenance training.

  8. Impact Report Project: Line 8 interiors pickup welder shielding gas leak. Problem Description: Gear clamps had worked loose and union had separated letting excessive shielding gas flow. After Before Union separated and clamps loose Union repaired with proper clamps Solution: Replaced gear clamps with proper clamps and re-taped to protect. Benefits: $16,644.00 annualized savings, Improve product quality. Sustainability: Process Audits/ Maintenance training.

  9. Impact Report Project: Correct gas flow on two welding machine in Line 8 Couplers and Rear Frame Areas. Problem Description: Found missing Gas Flow Restrictors causing excessive shielding gas consumption. Before After No restrictor in place. New restrictor installed Solution: Installed Gas Flow Restrictors. Benefits: $10,451.60 annualized savings, Improve product quality. Sustainability: Process Audits/ Maintenance training.

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