Measure Phase

As we now start the Measure Phase we must have a clear understanding of the current process.

To help us understand the process we needed to measure and document each stage of the changeover.
It was decided that firstly we should document every aspect of the changeover procedure no matter how small it appeared to be.
After collecting changeover data from several changeovers the detail involved in the process became surprisingly clear.

The team decided the best way to display the data was to input our data into a Gantt chart.
(see Fig 1 below).
We found this chart to be excellent in giving us a clear and accurate understanding of the time currently taken to complete each aspect of the changeovers.

Fig 1

Conclusions from Measure phase

• Currently takes 37 minutes from last spray cycle on Batch A to start of spray cycle on Batch B
• Cannot start PreWeigh on batch B until last unit on Batch A passes through Wet Weigh/Inspect due to CPU system constraint.
• Paperwork,Material Replenishment and clean down are done completely sequentially.
• Time taken for Tubing change and Nozzle clean by Engineering is 12 mins.
• 20 mins Drying time rule greatly restricts changeover time. 

Fig 2

                                                   Basic Flowchart for reference (Fig 2)

Fig 3

Fig 4

Fig 3 shows Re-circulation tubing which needs to be replaced during changeover.

Fig 5

Fig 4 shows shows spray machine internal unit.

                                                                                  Fig 5 shows spray machine external unit

Going forward to the Analysis phase

Going forward the key areas of focus will likely be on..

• Nozzle cleaning and Tubing change,
• Balancing of set up activities
• Constraints around CPU system and 20 min drying time

Define Phase

Define Phase

The purpose of this project is to reduce downtime on the production line during the changeover period between product batches. This is mainly due to the consecutive performance of multiple activities that are required to be carried out during the changeover period.

Problem Statement
The amount of downtime at the Spray work-step between changeover batches is too long, This impacts on production line efficiency which in turn causes downtime on subsequent operations thus affecting outputs.

What is the Scope?
All changeover activities required between batches at Spray work-step.

What is the Metric?
The Metric is the Spray Machine downtime, expressed as the lead time between end of spray of previous batch and the start of spray of new batch.

What are the benefits?
Reduction in Spray machine downtime.
Increase available production time/increase outputs.
Improve efficiency of manufacturing processes.

Tools used to Define problem

A brainstorming session was arranged between team members which highlighted many potential ideas during the creative phase.

Fig.2

Upon completion of the evaluation phase we had some very positive areas to focus on which will be analysed in detail going forward.
Some of these are pictured to the right.(Fig.2)

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     
Below is a basic flow chart of the relevant work steps.(Fig.1)

Fig.1

   

Along with our brainstorming session we displayed possible obstacles with the aid of a fishbone diagram as seen below in Fig.3.

Using the Fishbone diagram tool really helped us to highlight key obstacles we have to overcome as well as separating them into specific categories for focus. We found this method to be very productive.

Fig.3

On completion of the Define phase we believe the we are now more focused and have a clear understanding of the direction we need to take in order to complete this project.