1A. OPPORTUNITY: Return to Stock Process Improvement Team Manuel R. Leader Rick C.

Site/Plant: Inventory Control (RTS) Date : 05/10/2010 Members Joey T.

A3 Report Names
Group/Workcell/Site: St. Petersburg,FL Annual Savings (US$) : $24,550 Jorge M. Jaime V. Mentor

1B. CLARIFY THE PROBLEM: Key metric to impact: 5 & 6. DEVELOP & IMPLEMENT COUNTERMEASURES:
SMT Lines at STP have had an average OEE of 34% from October to May. OEE – SMT Lines

60% OEE – SMT Lines Problem identification Root causes Selected Countermeasure Who Target Finish
50%
Target = 55% Who: Operations-SMT 1. Define time standards Manuel 03/21/11 03/28/11
40%
2. Create a FIFO tag systems Joey 03/15/11 04/15/11
What: Waiting for material No
30%
03/21/11 04/01/11
3. Set material handlers rounds every 2 hrs Jorge
20%
Where: SMT Lines Standard 04/01/11 04/10/11
10% 4. Set process for IA to email SMT supervisors Jorge
When: Material is required for
0% when kit is done
Oct Nov Dec Jan Feb Mar Apr May processing 4/15/11
5. Create standard work for processing Jorge 05/01/11
2. BREAKDOWN THE PROBLEM: Waste(s) Identified 05/01/11 05/21/11
6. Train Jorge
Describe the Process:
Transportation [ ] 7. EVALUATE RESULTS:
How does the result compare to target? How well did the countermeasure (s) work?
Inventory [ ]
60 8 Motion [ ]
7
50
6 Waiting [ X] Turn Around Time (# hours per part) Summary of Results
40 80
30 4 3 Overproduction [ ] 70 Reduced bake time for MSD parts/moth by
20 2 1 Over-processing [ ] 60 83%
50
10
Defects [ ] Reduced late kits by 72%
0
0
RTS processing Part stockout Part not order
40 Target: 24 Reduced walking by 44%
Cycle Run time Material Scrap Skills unused [ ] 30
20 New standard for RTS cycle time: 2 min/part
10 Overtime costs decreasing
0
3. SET A TARGET (The challenge): Apr May Jun Jul

Improve _ Turn around time per part _from 72 hours to 24 hours 8. STANDARDIZE:
What Current Target
by June 2011 Means of Standardization:
When
Standard Work [X] Visual Aids [ ] Global Document /Procedures [ ] Training [X] Other [ ]
4. ANALYZE THE ROOT CAUSE:
___Method___ __Machine____ Process Audits:

No standard No way to track parts LPA [X] TPM checklist [ ] 5S Audit [ ] Other:___________________________ [ ]
No standard
cycle time in MSD ovens
process for MSD
part returns Next challenge:
Further changes to sustain improvement
No FIFO for part
processing Re-layout the RTS area.
Turn around
time = 72 hrs
Sharing with others:
How and with whom has this project been shared?

Poor layout of the RTS Presented to all in the Lean Council meeting 07/21. Shared with Besancon site.
Returning parts to RTS
is not a priority for SMT area
team
Lessons Learned:
List key lessons learned from this project

___Manpower__ __Layout______ LPA is critical to ensure current standard process is followed by all team members.
Form #: F-108 - Revision Date: 02/17/2012