Hide Notes 

Slide 1: Business Process Lean • Asheboro Plant “18”-"24” Rationalization Revision 11/29/01 ©2001 The Timken Company 1
Slide 2: Instancing Process Kaizen Event Instancing is the process by which new part number-inspection code information is entered into Asheboro’s manufacturing databases and verified for production. It includes: Transferring part-specific information from Corporate databases to Asheboro databases Verifying all the inputs have been transferred and that they are correct Running ICAD models to ensure product does not violate manufacturing rules Creating work instructions for the shop floor Procuring any needed tooling Coding the item as orderable ©2001 The Timken Company 2
Slide 3: Instancing Process Kaizen Event Objectives: •Reduce individual task times below Takt time •Decrease average instancing flow time by 15% (based on time to complete once job leaves queue) •Develop understanding of Lean concepts •Takt Time, Flow, Kaizen, Pull, Value Stream, etc. •Obtain buy-in from those not involved with the event •Implement changes by end of the week (One month max) ©2001 The Timken Company 3
Slide 4: Instancing Process Kaizen Event Baseline: Instancing Process - Task time vs Takt time chart Obtain dim ensional data Check for roller Obtain insp codes & assy no's. Check code requirem ents Make sourcing decision 10 10 18 35 307 90 120 52 90 23 11 30 5 60 30 Critical Path Tasks Send request to MSI team ASB Capability Analysis Load queue Load data in ASB databases Forging design Verify inputs vs. outputs Procure tooling ICAD verification ICAD error correction Code as orderable 0 Takt tim e 50 100 150 200 250 300 350 Duration (Minutes) ©2001 The Timken Company 4
Slide 5: Instancing Process Kaizen Event Method: •Defined current process using a process map •Map shows timing, duration, inputs, outputs, & responsibility for tasks •Evaluated each task in terms of value to customer •Envisioned and defined the ideal process •Eliminated non-value added activities that are not necessary and minimized those that are necessary •Attacked all forms of waste •Constructed two new processes based on the value-added steps of the current process and the future vision •Developed action plan to achieve the Phase I process •Next: Determine how to control the process and regulate its flow ©2001 The Timken Company 5
Slide 6: Instancing Process Kaizen Event Results: Instancing Process - Task time vs Takt time chart Obtain dim ensional data Check for roller 5 Obtain insp codes & assy no's. 5 Check code requirem ents Make sourcing decision Critical Path Tasks Send request to MSI team ASB Capability Analysis Load queue 5 Load data in ASB databases Forging design Verify inputs vs. outputs Procure tooling ICAD verification ICAD error correction Code as orderable 23 65 0 50 Takt tim e 100 150 200 250 300 350 52 90 10 80 120 10 10 18 30 155 152 30 55 30 Durations (Minutes) New Duration Time Savings ©2001 The Timken Company 6
Slide 7: Instancing Process Kaizen Event Results: Improvements Base Base with Forge Design Base with Edits Base with Cones Base with Errors Weighted Avg Critical Path Old 556 646 561 608 601 615 New 279 374 279 279 324 311 Savings 277 272 282 329 277 304 % 49.8% 42.1% 50.2% 54.1% 46.1% 49.5% 7 ©2001 The Timken Company