Lean Article.
Support Slides.
Slide 1. What We Have Done:
People Involved
Area Manager
Head of Logistics
Executive Management
Head of Operations
Plant Managers
Executive Management
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Slide 1
Slide 2. Type and frequency of customer demand
and demand flow
CS
X trucks per day
XX - XXX
Cylinders
# of trucks arriving
from customers
Prep / Sort
Customer and
LifeGas Cylinders
Customer
XX Cylinders
XX%
WE
FS
PD
LifeGas
XX Cylinders
XX%
Cylinders
Filled
VGLs
XX Cylinders
XX%
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O2 Small Pin
Index
XX Cylinders
XX%
O2 LIV
XX Cylinders
XX%
O2 Large
XX Cylinders
XX%
Other Gases
XX Cylinders
XX%
Slide 2
Slide 3. Current State:
Step 3: Map the current value stream
Deliver from
Customer
Deliver to
Customer
Customer
Office XXX
Production Ticket
I
Range: 0 – 1400
Avg.: 700
Prep
2 FTEs
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Delivery
Ticket
Production Ticket
I
Range: 0 – 1400
Avg.: 700
Filling
2.5 FTEs
I
Range: 0 – 1400
Avg.: 700
Loading
8 FTEs
Slide 3
Slide 4. Current State Analysis and Future State
Development
Create new plant flow and layout of facility
— “poke-yoke” (mistake proof) where possible
4 Cylinder Staging
5 Filling
6 Full Cylinders
7
Full Other Gas Cyl
8 Bio-med - Dirty
9 Bio-med Clean
10 Forklift
11 Technical Cabinet
12 Office Ent ry
13 Cylinder Testing
1S
17d
76 ft
15
15 Large O2 Filling
53 ft
88 ft
21 ft
114 ft
6S
6L
1L
104 ft
75 ft
108 ft
42 ft
2a 3a
17b
8b
108 ft
7a
68 ft
10 ft
9a
3b 2b
11
12
58 ft
79 ft
79 ft
16c
15
88 ft
227 ft
13
5
19
135 ft
7b
18
10
16 Hydro Storage
17 Medical excess
18 Nitrous Cage
5 ft
98 ft
14a
14b
1 truck
Empty
19 Second Office
Full
Retest
201 ft
17a 8d
16b 9c 8c 17c
5
22. 04.2010
1
Cylinder Drop Off
2 Prep Area
3 Hydro
4 Cylinder Staging
5 Filling
6 Full Cylinders
7
Full Other Gas Cyl
8 Bio-med - Dirty
14 VGL Filling
15 Large O2 Filling
Full
Spec
Gas
Customer Empty
M / T / W / T / F / Asset
130 ft
97 ft
29 ft
130 ft
Stage
81 ft
16 ft
67 ft
20 ft
5 ft
HQAA
45 ft
HQAAHQAA
HQAAHQAA
Asset
Hydro
11 Technical Cabinet
12 Office Ent ry
13 Cylinder Testing
Future State Houston
20 ft
Prep
9 Bio-med Clean
10 Forklift
145 ft
120 ft
105 ft
10 ft
196 ft
9b
8a
82 ft
72 ft
4
16a
227 ft
14 VGL Filling
— Standardize processes where possible
— Look for opportunities for visual management
Current State Houston
10
Lanes
— Reduce cross contamination of products
where possible
3
Hydro
Driver
— Eliminate excess distance traveled
Cylinder Drop Off
2 Prep Area
HQAA
Full MH /
Asset
— Assess where redundancy exists
1
Driver Lanes
— Review the current state “spaghetti” diagram
Cust..
Cust
Pick
“Simplify”
16 Hydro Storage
17 Medical excess
18 Nitrous Cage
1 truck
19 Second Office
22. 04.2010
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18
Slide 4
Slide 5. Measure Current Performance
“Easy to Read Fashion”
227ft
184ft
Empty Large: 306Ft
233ft
Empty Small: 234Ft
Full VGL: 227 FT
VGL 227 ft
Full Large: 184FT
Small 234 ft
Full Small: 233FT
Large 306 ft
Empty VGL: 227Ft
Texans
25% added to distance due to searching for cylinders since lack of order
exists
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Slide 5
Slide 6. What We Have Done:
Current State Assessment
“5 Ys”
5Ys Overview
— Lincoln Memorial Story….
— Provide simple overview of why we will be asking
so many questions of the employees
“Why 5S Is So Important”
5S Exercise
— Paper simulation searching for numbers while 5S
is applied to the “workspace”
— Physically demonstrates to employees how 5S
can reduce workload
— Sort / Set In Order / Shine / Standardize / Sustain
Day 1
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Day 2
Day 3
Day 4
Day 5
Slide 6
Slide 7. What We Have Accomplished:
Before & After
Before
After
— Unorganized and lacking clear
placement of product
— Excess inventory
— Management challenge
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Slide 7
Slide 8. Large Cylinder Storage
Before
After
— Lack of organization
— Color coded painting on floor for
clear separation
—
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Installation of “visual” Kanban using
floor coloring
Slide 8
Slide 9. What We Have Accomplished:
Before & After
Before
After
— Drivers randomly dropping product
where space is available
— Create prioritization lanes for what to
be filled next – visual management
— Co-mingled Asset and Customer
owned cylinders
— Separate Customer owned and
Asset cylinders
— Add mural and signature board for
commitment to the process
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Slide 9