Lean Basic PDCA Project Process

An MFCS Metform team defined a safety concern driven by transportation and motion associated with movement of parts and, as a risk of lift truck/pedestrian accidents due to the high volume of lift truck traffic involved with moving parts long distances.

Data was collected to determine the volume of lift truck traffic and traffic patterns.  Pictures were taken and reviewed, distances were measured, and spaghetti diagrams were developed to illustrate the observations. The team talked to material handlers and employees, and gathered input, which was used to complete a 5 Why exercise to help identify the root cause and potential solutions.

The root cause of the problem was determined to be that equipment and machines had been added over time to increase capacity to meet growing orders, but that scales, used to weigh parts in nearly every aspect of the manufacturing process, had not been added along with the equipment. Scales that were in place were located long distances from the processes that they supported.

Shop floor drawings, spaghetti diagrams and input from employees were used to develop potential alternative locations for existing scales and locations where new scales might be added.  Consensus was reached on the number of new scales required, the best locations for them and the existing scales based on achieving the minimum distances required for transport and support of lean product flow.

Existing__8,__9,__10___Wheelabrate_Scale_Location  New_Scale_(Wheelabrate)                New_Scale_8,_9,___10  Relocated_Scale_(Assembly)

Existing, new and relocated scales reduced lift truck distance traveled by many thousands of feet per shift.