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Impact Report

Impact Report. Project: Duraplate Tower Savings. Problem Description: Valve stuck open and level too high causing overflow. Solution: Repaired valve and reprogrammed water level. Benefits: $6,118 annualized savings & improved environmental standing.

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Impact Report

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  1. Impact Report • Project: Duraplate Tower Savings. • Problem Description: Valve stuck open and level too high causing overflow. • Solution: Repaired valve and reprogrammed water level. • Benefits: $6,118 annualized savings & improved environmental standing. • Sustainability: Control alarms changed & Monthly audit reports. Overflow Changed Alarms Stuck

  2. Impact Report Project: Floor Station#2 and Station#3 Bottleneck Elimination . Problem Description:Station#2 and Station#3 cycle time exceeded the south plant cycle rate of 31min. Before After • 47 Min Avg. Cycle Time • Inadequate Labor Count • Poor Utilization of Production Kits • 29 Min Avg. Cycle Time • Added 2 Operators • Proper Utilization of Production Kits Solution:Increased manpower, modulated production packages, provided standard work flow, and increased visualization of manning for supervision. Benefits:$17,136 annualized savings. Sustainability:Product / Process design change.

  3. Impact Report Project: Floor Station#1 Bottleneck Elimination . Problem Description:Station#1 cycle time exceeded the south plant cycle rate of 31min. Before After • 42 Min Avg. Cycle Time • 10 Min Changeover • Inadequate Labor Utilization • 29 Min Avg. Cycle Time • -Defined work patterns • -Eliminated wait on weld • operation (added a jig) • 6 Min Changeover • -Point of use containers for • changeover pins • -Additional prints • Proper Labor Utilization • -Standard work Solution:CI event reduced changeover time, created standard work, and changed the production process. Benefits:$455,621 annualized savings. Sustainability:Process design change.

  4. Impact Report Project: Reduction in Raw Material Inventory Problem Description: The current raw material inventory in Metal fab is undocumented, in-excess quantity and in-excess raw material types. Solution:Reduction in unnecessary raw material numbers required on floor. This is in conjunction with SAP implementation and cleaning up raw material part number list. Benefits: Total Cost Savings = $43,000/yr. BEFORE AFTER Reduction in Raw Material Inventory $147K $97K Reduction in Raw Material Numbers on floor 61 32 Reduction of Raw Material Numbers in MRP system 2500+ <100 Sustainability:SAP Implementation team member is using the updated material list for correcting all 9000 existing part numbers product structures. Product design using Design for manufacturing guidelines for new parts.

  5. Impact Report Project: Two at a time Bullhorn Punch Problem Description:Have a two position form and a one position punch in bullhorn punch and form cell. The punch is a bottle neck. Solution:Replace the one at a time setup with a two at a time setup. Before After Benefits: Free up about 34 minutes production time per day. $5,200 annualized “soft” savings. Cost was about $900. Sustainability:Definitive Process change.

  6. Impact Report Project:Line 5 floor drill re-layout Problem Description:Associates must use two ladders for the attachment of the plywood and Duraplate on the inside of the nose liner. This creates a serious safety issue in which Line 5 has had three recordable accidents in 2006 alone due to this problem. After Before Solution:Created a nose ply cart to carry all of the needed tools, provide a platform for the operators to work off of, it has on-board manifolds so it eliminates the need to pull down two air lines from the overhead hose reels, and it has incorporated the actual ply cart into it so there is only one trip needed from the lift to the nose of the trailer. Benefits:The Elimination of the extremely hazardous act of constantly having operators on unstable ladders. Sustainability:The ladders have been eliminated from the area and the nose cart is being added to the standard work instructions.

  7. Impact Report • Project: Install Protective Padding • Problem Description: Potential damage to rear frame paint finish due to contact with powdercoat unload lift hook Powdercoat Unload Hook Urethane pads added to protect frame header from damage.

  8. Impact Report Unload Station Mezzanine Unload Station Support Bar UHMW Sheet & strips added to mezzanine & support bar to protect frames from damage • Solution: Install protective padding on lift hooks and at unload station • Benefits: Prevent paint finish damage caused by contact with lift hook and unload station structure • Sustainability: Pads are easily installed and resistant to wear. Checking for wear will be added to the operator PM list

  9. Impact Report Project: Better sheet utilization - 03S06296 Problem Description: The sheet utilization on Landing gear pad (13S01364/65) is poor. Scrap piece Before Landing Gear Pad 13S01364 After Apron Corner 03S06296 Solution:To produce part using scrap from Landing gear pad (13S01364/65).Part 03S06296 (apron corner) fits well in skeleton with better sheet utilization. Benefits:Savings in raw material (nesting and making part of scrap) = $43,000/yr. Sustainability:Process routing change.

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