Process Charting Conventions

Process
Decision
Delay
Manual Operation
Definition
System
Off-Page
Connector
On-Page
Connector
Level 1 "To-Be"
11/6/2001 To-Be Process.igx hfg
Plan IM
Production
1-N
Assign Job
2-N
Start
Set
Mold/Recipe
3-N
Start/Run Job
4-N
Schedule
Quality
Pack and
Deliver
5-N
Customer
Injection Molding
LEAN Job Execution Process
"To-Be" Process Level I
Obs
7-N
Material
Operational
Availability
Note: Shape 1, Level I
Schedule (Predecessor to Planning)
PCL schedule is for end items, no schedule for manufacturing of IM parts, put out on Mondays for the week,
but updated daily
On Monday stockchaser puts into schedule: buffer sizes, inventories, line schedule.
Daily schedule changes master schedule
Goes to production planner Rossi (see diagram), press/mold availability : daily mold pull/set schedule
Daily suvpvr daily shift transition schedule
Rossi's daily plan is adjusted by supervisor based on changes
STS initiated several hours b/4 shift, 15 min overlap
Plan Production
B/4 every shift review with operators, fork truck operators, verify manpower is available

Note: Shape 2, Level I

Assign Job
Note: Shape 3, Level I
Set Mold/Recipe
Recipe sometimes called "process"
No designated areas for specific molds, they move all over, no inventory/tracking
4 major storage areas
SM=service man
Load recipe from controller or get paper copy and manually enter
-------
(Molds left in machine after job, pulled at start of next job)
------
Variation caused when machine shut down (no mold change) and same job restarted. No standard process for
restart as opposed to new job startup.

Note: Shape 4, Level I

Start/Run Job
Start Machine
Verify Recipe
Run Order to completion
First part inspector: geometry, some parts need to be warm for assembly
First piece assembly may discover problem after start, no FIFO, chase down of nonconforming necessary
(greg)
Note: Shape 5, Level I
Pack and Deliver
T2
assume start and run
SM signals MH
tag type depends on subsequent operation
trucker takes racks to designated storage area, brings back empty
mh removes superfluous cardboard
T1:
mh does visual inspector
conditioning (remove flash, poke hole)
proper pack (orientation)
id container

conditioning (remove flash, poke hole)

proper pack (orientation)
id container
transport racks to banks

Note: Shape 7, Level I

Observations:
Rossi's schedules are not the end-all it was intended; a lot of fingers in pie; optimize specific situation to detriment
of total picture
Buffer planning (volume and floor plan changes throws off)
Little planning to remove molds after job (need to be engineered based on standard demand pattern)

Plan IM Production "To-Be"

11/6/2001 To-Be Process.igx hfg
Stockchaser Stockchaser
Prod_Planner Prod_Planner
ShiftSupvr ShiftSupvr
Systems Systems
Navigation Navigation
Start
1-N
Return to
Level 1
Assign
Job
7
Create /
Maintain
Operating
Plan
2-N
Develop /
Maintain
Schedule
Inventory Data
3-N
Develop
Weekly Plan
4-N
Develop Daily
Plan
5-N
Release and
Validate Plan
6-N
Notes
-N
OA
Manpower
8-N
PC&L
Inventory
9-N
Note: Shape 1, Plan
IM Production Planning
Notes
Planner needs to allocate desired resources
Demand is known if engineered buffer
Buffer needs to be maintained; chaser does not have to interpret, buffer speaks for itself.
Current design does not have sufficient space; may have to run multiple small runs - rapid changeover time
becomes critical (balance between cost of maintaining buffer and cost of multiple changeover
Do you want to design a stockchaser function or an engineered buffer.
Pull system is notice; buffer is contingency system
Working to inventory causes variation. Visual inventory enables lean

Note: Shape 2, Plan

Plan IM Production
Create / Maintain Operating Plan
Drives OA and manpower at macro level
Acquiring weekly production data
This is a long-term plan, done weekly, 6 week view

Note: Shape 3, Plan

Plan IM Production
Develop / Maintain Schedule Inventory Data
Visual inventory
Must Know Consumption (pull system, tightly-engineered buffers, scanning / bar code systems)
At worst case use stockchaser
At best case use engineered buffer or some combination
CSF = How we handle Schedule Inventory Data
ACC = Implement Bar Code Inventory system; may eliminate stockchaser

Note: Shape 4, Plan

Plan IM Production
Develop Weekly Plan
Includes:
demand
mold and press data
run time
manpower (vacation and sick leave)
equipment repair
Subset is 24-hour snapshot

Note: Shape 5, Plan

Plan IM Production
Daily Plan (Snapshot)
Daily plan by shift and transition, 24-hour view of weekly plan (focused view of Weekly Plan).
If automated, does not have to be separate document.
This is a "rolling" plan, see attached diagram
Additional notes (Team 2 9am 10/30/01 Flipchart A-4)
Real-time Inventory
Scrap information by mold / press combination

Daily plan by shift and transition, 24-hour view of weekly plan (focused view of Weekly Plan).
If automated, does not have to be separate document.
This is a "rolling" plan, see attached diagram
Additional notes (Team 2 9am 10/30/01 Flipchart A-4)
Real-time Inventory
Scrap information by mold / press combination
Run time by mold / press combination
Determine number of people required and arrange for entire 24-hour day
Factor in attendance (14% absentee rate)
Leasing new machines
Centralized source of communications (web-based)
Machine status
Mold status
Mold try-outs
Toolroom status
Maintenance / trades status
Buffer size
Operating plan for each press

Note: Shape 6, Plan

Plan IM Production
Release and Validate Plan
Establish accountability to maintain weekly plan integrity
CSF = Process activity for corrective action

Note: Shape 8, Plan

Plan IM Production
Systems Input #1
CSF = Have
Operational Availability
Manpower
Note: Shape 9, Plan
Random Thoughts
Standard production plan should help eliminate parts scrapped between shifts; hopper suck-outs
Energy conservation - timely equipment shutdowns
Assume engineered buffer, flat schedule
Note: Shape 9, Plan
Plan IM Production
Systems Input #2
Flat scheduling weekly from PC&L
Engineered buffers
Usage (average daily + demand variation)
Losses due to assembly FTTQ (First Time through Quality)
CSF =
Have PC&L Schedule
Inventory Data
Know quality-related losses (assembly first-time quality or molding production scrap

Assign Job "To-Be"

11/6/2001 To-Be Process.igx hfg
Prod_Planner Prod_Planner
ShiftSupvr ShiftSupvr
SM SM
ForkTruck ForkTruck
ReliefOp ReliefOp
Systems Systems
Navigation Navigation
Start
1
Distribute
Daily
Plan
2-N
Verify/Adjust/
Finalize
Assignments
5-N
Return to
Level 1
to Set
Mold/Recipe
6
Plan
Production
Distribute
Mold Set
Packets
4-N
Communicate
Daily Plan
3-N
Mold Set
Packet
7-N
Note: Shape 2, Assign
Assign
Distribute Daily Plan
Production Planner distributes the released Daily plan to shift supervisor
Note: Shape 3, Assign
Assign
Communicate Daily Plan
Previous shift supervisor collaborates with current shift supervisor to ensure smooth hand-off of daily plan
Daily (24-hour extract of weekly plan) plan executed across 3 shifts, goes to each shift transition
Possibly post plan in central location or at workstations
Assignments are communicated to workforce during 5-minute shift startup meeting
Relief operator is directed to cover for missing personnel
ACC =
Shift Overlap Pre-start meeting
Check who is here
Hand out assignment
Safety Review
Review quality
Man stations all the time; none left unattended
Relief goes to straight 8 hours
Packets - chapters for each job classification, kept on mold with Velcro? Given at mold set and kept at
machine?
SM - Mold Set / Pull / Start / Stop checksheets
MH - Pack diagram
Mold setter
Electrical diagram
Water hook-up
Job instructions for every aspect, material list (kit)
SM, FI, MH - inspection checklist
What is a "good" part

INH = Added Time
More resources needed - added cost
Attendance
Need availability of paper and ink / toner

CSF = Changes relief schedule
Next Shift supervisor needs to be in 1 hour early
Current shift supervisor on floor
Follow standardized work
Improved access to OSC information

Note: Shape 4, Assign

Assign
Distribute Mold Set Packets
Each machine / mold combination has a packet of configuration information that is available at the machine
until a mold change is made.
Some combinations have no info packets.

Note: Shape 5, Assign

Assign
Verify/Adjust/Finalize Assignments
The shift supervisor verifies assignments based on resource availability. In a small department, this may be done
2-4 times per shift.
Verify that all resources are in place
Department walkthrough:
Workstation manned, etc
Cause of changes: manpower, equipment failure, quality
Planned maintenance for mold / press that are down
Other inputs to this that may cause changes to assignment:
people resources
material resources
machines/tooling
quality problems
schedule change (Needs definition)
CFF = Communication Feedback Loop
ACC = Better and concise communication tool
INH = Too many people / channels

Note: Shape 7, Assign

Assign
Mold Set Packet
Electrical
Water
Mold/Press attributes (specific information)
Mold/Press recipe
Job Instructions and visual
mold pull, set, start job sheets
Set Mold/Recipe Process "To-Be"
11/6/2001 To-Be Process.igx hfg
PreSet
1-N
Pull Mold
2-N
Set Mold
3-N
Load Recipe
4-N
Prepare to
Inject Plastic
5
Start
To Level 1
Set Mold / Recipe
To Assign
Job
Beneficial
Attributes
7-N
Additional
Notes
8-N
Process
Control Plans
9
To
Start/Run
Job
6
Note: Shape 1, Set
Set Mold / Recipe
Pre-Set Notes
ACC =
Serviceman to locate mold and associated "kit" from designated area / rack
Serviceman to test and preheat on MSI (this replaces Hot Tip Check), and may be done on previous shift
Quick-change-ready

Note: Shape 2, Set

Set Mold / Recipe
Pull Mold Notes
INH =
Locating crane box sign-out
Eyebolts available on mold
Available die straps part of each mold, need better control
For safety, ensure required die strap(s) on the mold

Note: Shape 3, Set

Set Mold / Recipe
Set Mold Notes
ACC =
Mold Set Teams
Expect certified mold from toolroom "checklist"
Features, Failure mode, visual inspection, TBD

Note: Shape 4, Set

Set Mold / Recipe
Load Recipe Notes
ACC =
"Certified" recipe book for every mold/press combination
Refer to packet
Develop new recipes "checklist"

Note: Shape 7, Set

Set Mold / Recipe
Beneficial Attributes / Enablers
Decoupled molding separates mold from press; by decoupling, monitor mold conditions (DOE) to
generate template curves. Transportable from press to press by matching mold curve.
Validate and PPAP once
Install pressure transducers
DOE
Education
Tie into MatTec
Recipe Level Qualification:
Qualify: Serviceman
Validate: SPC
Certify: Another level of (Phase III) process engineering protocol to establish UCL LCL
Job Packet: Electrical, water diagrams, pre-stage kit contents, (any pertinent information)
Accountability to run prescribed recipes, collect reasons for deviations
Electronic on-line storage of information and ownsership to ensure up-to-date / accuracy: Packet and
Recipe (PDM Data Integrity), current data

Job Packet: Electrical, water diagrams, pre-stage kit contents, (any pertinent information)
Accountability to run prescribed recipes, collect reasons for deviations
Electronic on-line storage of information and ownsership to ensure up-to-date / accuracy: Packet and
Recipe (PDM Data Integrity), current data
a) Ability to locate tools, job packets, kits;
b) Prestage and kit
Standardization of all elements including workplace organization, kits/locations, mold trackability,
toolroom storage
Mold inventory / physical mold stoarge areas allocated
Operating plan limits press/mold combinations; optimize physical combinations
Equip mold with legs to decrease storage requirements for racks; safer to hook to crane (no standing
on racks)
Consistent operating plan
Training / education on equipment, process, systems; and documentation

Note: Shape 8, Set

Set Mold / Recipe
Additional Notes
Access to molds for pulling
IBN as 2nd option to MSI
MSI in mold storage area
Feet on molds, eliminate racks and their floor space
WPO for pulling / setting molds
Standardize water fittings (size and gender), "kitting"
Overall mold storage, staging, and tracking
Production and toolroom - in and repairs done
Library for molds
Mold packet only for:
Water
Hydraulic
Recipe
Pin Sheets
Clamping init
Need method of documenting / communicating reasons for changes / deviations from normal, base
recipe
ACC = SPC and SM must be available
Decoupled molding
Business case for upgrading presses
(Lease of equipment)
INH = SPC and SM used as extras

Recipe (PDM Data Integrity) Current Data

Note: Shape 8, Set (continued)
Decoupled molding
Business case for upgrading presses
(Lease of equipment)
INH = SPC and SM used as extras
PreSet "To-Be"
11/6/2001 To-Be Process.igx hfg
SM SM
Electrician Electrician
ShiftSupvr ShiftSupvr
Systems Systems
Navigation Navigation
Prepare Pre-Set
Start
To Pull
Mold
6
To Set
Mold/Recipe
To Level
1
Locate Mold
and "kit"
3-N
Test and
Preheat
5-N
Mold / Kit
Location
9-N
Assemble Kit
1-N
Move kit to
kit storage
area
2-N
Update
Location
8-N
Job Packet
7-N
Stage
Mold
4
Note: Shape 1, PreSet
Set Mold/Recipe
Prepare PreSet
Assemble Kit
ACC = Assemble "kit" per job packet
Kit (Roll-around)
Common water lines / connections (size and gender)
Maintain current equipment on racks
Location of eyebolts and straps (only removed if operation inhibited)
Electrical cables
Hydraulic hoses
Clamps
Spare "dummy plug"
At press (stationary)
Pan op grease with brush
Location of eyebolts and straps (only removed if operation inhibited) - common location when removed at
press
Location for good / bad ejector rods
Location of ejector bolts (tapered?)
Mold Spray
Office
Crane Boxes
Serviceman
Standard Tool box

Note: Shape 2, PreSet

Set Mold/Recipe
Prepare PreSet
Move Kit to Storage Area
ACC = Database of designated storage areas
Transport kit to designated kit storage area
Identify, track, footprint, maintain, flow
Feet on molds (conserves floor space)
Location of molds (storage areas)
Tracking info on whiteboard in supervisor's office
Label locations: mold floor plan
Update mold ID
Festooning location for MSI water hookups
Location / use of IBN (check electric / heat mold)
Flow of molds - molding / toolroom

Note: Shape 3, PreSet

Set Mold/Recipe
Prepare PreSet
Locate Mold and Kit
ACC = Locate mold and associated "kit" from designated rack/area
Note: Shape 5, PreSet
Set Mold/Recipe
Prepare PreSet
Test and Preheat
Test and preheat on MSI (replace Hot Tip Check), possibly on previous shift
If test fails, move to toolroom for repair
If test passes, move mold to staging area
Note: Shape 7, PreSet
Job packet
Note: Shape 8, PreSet
Update system with location
Note: Shape 9, PreSet
Location of mold and kit
Pull Mold "To-Be"
11/6/2001 To-Be Process.igx hfg
SM
ForkTruck
ShiftSupvr
SPC
Systems
Navigation
Start
To Set
Mold/Recipe
To Level
1
To Set
Mold
6
Packet
7-N
Get Last Part
2-N
Pull Mold
3-N
Return
previous
jobs
packet
4
Get Packet
1
Recipe to
SPC
5
Note: Shape 2, PullMold
Pull Mold
Get Last Part
Need to have the last part run from mold before shutdown kept at press as startup aid for next run. The
part should accompany the mold and be identified. Part is used for next startup or tool room.
Note: Shape 3, PullMold
Set Mold/Recipe
Pull Mold
Pull Mold
INH = If the Rack/Table is not available; This step could be eliminated if mold equipped with feet
INH = Locating crane box sign-out
Eyebolts available on mold
Available die straps
ACC = Have packet on-line
Note: Shape 7, PullMold
Job packet
Set Mold "To-Be"
11/6/2001 To-Be Process.igx hfgf
SM
Systems
Navigation
Start
-N
Set Mold
1-N
To Set
Mold/Recipe
To Level
1
To Load
Recipe
3
Packet
4-N
Verify Material
2
Note: Shape 1, SetMold
Set Mold
Start
Mold set teams
Expect Certified Mold from Toolroom "Checklist"
Note: Shape 1, SetMold
Set Mold/Recipe
Set Mold
Operate Crane
INH = If the crane is not functional
Note: Shape 4, SetMold
Job packet
Load Recipe "To-Be"
11/6/2001 To-Be Process.igx hfg
SM
SPC
ShiftSupvr
Systems
Navigation
Start
To Level
1
Prepare to
Inject
Plastic
6
Look up
Recipe
2-N
Found
3
Yes
Load Recipe
5-N
Formulate
New Recipe
or Duplicate
Existing
Recipe
4-N
No
To Set
Mold/Recipe
Turn on
power
1
Note: Shape 2, LoadRecipe
Load Recipe
Look Up Recipe
Verify recipe printed file name and revision date
Match file name and revision date in press CPU
Why wait until this point to confirm recipe?
Recipe should be part of packet, known status on schedule
Will this job be run to certify a recipe?

Note: Shape 4, LoadRecipe

Formulate/Duplicate Recipe
If an existing recipe for the machine/mold combination does not exist or cannot be found, it is necessary to have a
recipe made for that combination, either from scratch or by duplicating and optionally modifying an existing recipe.
Depending on the shift, this may be done by the SPC person or Shift Supervisor.
INH = Time lost
No effort to optimize a duplicated or new recipe, which may lead to quality problems or lost set-up time.
Note: Shape 5, LoadRecipe
Load Recipe
Load Recipe
Call up file
Review and verify settings
If no match, call up file, review settings, reset to match recipe
If recipe fails to load, there may be a CPU fault, requiring maintenance
Certified Recipe
Mold Protect
Designated People and Processes
Verified Recipe
Range for mold settings
Know process capabilities
Recipe that will consistently produce good parts
After sign-off put in DCC
Team-SPC, Process Engineer to develop
PPAP Process to certify
Issues: Time validation of PPAP, new molds on specified press
CFF = CPU Fault - parts are no longer available for commonly-used
GE controllers
CSF = Duplicate recipe in CPU
Look at start/run process block
Concern: Open-loop press- no feedback;
how can process recipes be used?
Operating Plan Limits (Designate mold/press combinations)

Prepare to Inject Plastic "To-Be"

11/6/2001 To-Be Process.igx hfg
SM SM
ForkTruck ForkTruck
HVAC HVAC
Systems Systems
Navigation Navigation
Start
Dry Cycle
Press
3-N
To Set
Mold/Recipe
To Level
1
To
Start/Run
Job
8
Prepare for
First Part
5-N
Check Oil
and water
6
Workstation
Setup
Process
1-N
Verify Mold
Protect
2
Verify Mold,
Barrel Heat
4
Verify Gates
7
Note: Shape 1, PrepInject
Prepare to Inject Plastic
Workstation Setup Process
Steps:
1. Correct Rack INH
2. Correct Fixture CSF
3. Perform model changeover CSF
Note: Shape 3, PrepInject
Prepare to Inject Plastic
Dry Cycle Press
INH = If the core needs adjustment
Note: Shape 5, PrepInject
Prepare to Inject Plastic
Prepare for First Part
Modify recipe settings for 1st inject
Check oil
Verify gates

Workstation Setup "To-Be"

11/6/2001 To-Be Process.igx hfg
SM
ForkTruck
HVAC
Systems
Navigation
Start
To Set
Mold/Recipe
To Level
1
To Inject
Plastic
4
Bring proper
containers
2
Refer to JIs
and Pack
Diagram
1
Communicate
with
Serviceman
3-N
Job Packet
5-N
Note: Shape 3, WS_Setup
Workstation Setup
Communicate with Serviceman
Do not start packing parts until serviceman gives O.K.
Follow startup procedure (needs more definition)
Note: Shape 5, WS_Setup
Job packet
Start/Run Job "To-Be"
11/6/2001 To-Be Process.igx hfg
Initiate Production
Sub-Assemble
Run Production
SM SM
ShiftSupvr ShiftSupvr
HVAC HVAC
Trucker Trucker
FloorInspect FloorInspect
SPC SPC
Systems Systems
Navigation Navigation
Start
Produce
First Shot
2-N
Adjust to
obtain Filled
Piece
3-N
Notify
Material
Handler
of
Good
Parts
7
Submit
First Piece
8-N
Run Parts
Adjust as
Required
9-N
Receive Parts
10-N
Assemble
Parts
11
Inspect Parts
12
To Pack &
Deliver
14
To Level
1
Shut Down
13-N
Settings
Out of
Recipe?
5
No
Investigate
6-N
Yes
Notify
Material
Handler
of
Scrap
1
Update
records
15
Note: Shape 2, Run
Start/Run Job
Prepare and Produce First Part
Steps:
1. Load barrel
2. Spray Mold
Note: Shape 3, Run
Start/Run Job
Adjust to Obtain Filled Piece
The set points are adjusted to produce a good part, and the water is turned on.
Process may need adjustment due to:
Press-related issues
Environment (temperture, humidity)
Quality-related issues
Mold-related issues
Material-related issues
Noted on Run Sheet after adjustment has been verified to correct the situation
CFF = Both steps must be completed or failure will result.
INH = Adjust of set-points
ACC = Process ranges to handle anticipated environmental and material fluctuations

Note: Shape 6, Run

Start / Run
Investigate Adjustments
SPC is asked to investigate the need for adjustments to compensate for variables:
Process may need adjustment due to:
Press-related issues
Environment (temperture, humidity)
Quality-related issues
Mold-related issues
Material-related issues

Note: Shape 8, Run

Start/Run Job
Submit First Piece
The first piece is submitted by the Serviceman to the Shift Supervisor and Floor Inspector for approval. It may
also be submitted to Pack & Deliver and/or Subassembly for check out before the production run is started.
Only accurate if their is no failure. If there is a problem trades and supervisor will be involved.
CFF = This step is critical; if part fails inspection, process can not proceed until fault is corrected.
Note: Shape 9, Run
Start/Run Job
Run Parts and Adjust
This step involves the Serviceman, the Material Handler/HVAC, and Trucker to monitor the quality of parts
produced.
The inventory is monitored by the Supervisor and the Trucker.
INH = Both steps are inhibitors
Record any recipe modifications
What conditions to stop production?
Need to include exception subprocess: who can do what, when, how

Note: Shape 10, Run

Start/Run Job
Receive Parts
This step involves molded parts, purchased parts, and the inspection of incoming parts.
INH = Receiving and inspecting parts are inhibitors
Note: Shape 13, Run
Start / Run
Shut Down
Save last piece at shut down every time for quality check and to use when re-starting job next time.
Pack and Deliver "To-Be"
11/6/2001 To-Be Process.igx hfg
Conveyor Conveyor
MatlHandler MatlHandler
HVAC HVAC
Trucker Trucker
Systems Systems
Navigation Navigation
Start
Verify
Container
Availability
5-N
Pack Part
8-N
Return to
Level 1
Signal for
Trucker
9-N
Truck to
Designated
Location
10-N
Bring Back
Empties
11-N
Prep
Rack
per
Job
Instruction
6-N
Part
conveyed
to MH
1-N
Perform
Visual
Inspection
2-N
OK
3
Yes
Defect
Process
4
No
Add content
7-N
Job
Instructions
12-N
Level 2
Discussion
Notes
Note: Shape 1, PackDeliver
Pack & Deliver
Part Conveyed to Material Handler
INH =
Workstation needs to be setup for tugging
Parts are damaged when ejected/dropped onto nets
Wrong / misadjusted belts cause parts to slip
Some conveyors too steep
Parts are damaged when jams occur
Do not sort startup parts

ACC =
Possibly use pick & place for larger parts
Index belt / conveyor pace
Sensors at workstation to detect backups, signal alarm
CSF =
PM for conveyors
Need to collect data over a 1 week period as to conveyance damage

Note: Shape 2, PackDeliver

Pack & Deliver
Visual Inspection
Detailed inspection of part by Material Handler
First part in rack
Short, flash
All screw bosses
Oil
Visual check during rack pack
Know areas identified
Last part in rack
Short, flash
All screw bosses
Oil
CSF =
Communication board at each station for ongoing communication
What's running
Current part issues
Job Instructions
Visual Aides
Pack Instructions
CFF = Poor inspection
ACC =
Train Inspector/operator
Scrap report / data collection
Need measurement mechanism
INH = Lack of cross-training

Note: Shape 5, PackDeliver

Pack & Deliver
Verify Container Availability
The Material Handler must verify the availability of the proper container, following pack instructions
Look at condition of container; tag and send to repair if damaged
Note: Shape 6, PackDeliver
Pack & Deliver
Prep Rack
The Material Handler and Trucker prepare the rack
Follow job/pack instructions
Remove old tags / place new tag
Look at condition of container; if damaged, tag and send for repair
CFF = Incorrect tags
ACC = Pre-printed Tags
INH = Return from assembly

Note: Shape 7, PackDeliver

Pack & Deliver
Add Content
Per Job Instruction
Flex hinge
Trim / Condition if required
Not at workstation
Instructions
Approval (PPAP)
Verification
Sub Assemble
Follow Instructions
More inspections of part by Material Handler
Floor Inspector focus is to monitor the process

Note: Shape 8, PackDeliver

Pack & Deliver
Pack Part
Place good part in appropriate container
Following Job Instructions, Pack Instructions
ID with correct tag
Look at condition of container; tag and send to repair if damaged

Note: Shape 9, PackDeliver

Pack & Deliver
Signal for Trucker
Need consistent method of signaling for fork trucks (lights, flags, radio)
Look into using roller conveyor to allow Material Handler to remove / stage full bin and move in empty
Use tuggers on scheduled routes
CFF = Trucker not available
ACC = Enforcement of job duties
INH = Lack of synchronization

Note: Shape 10, PackDeliver

Pack & Deliver
Truck to Designated Location
Pull racks when full
Replace empty
Deliver to (buffer) location
CFF = Trucker not available
ACC = Enforcement of job duties
Tugger Delivery
INH = Lack of synchronization

Note: Shape 11, PackDeliver

Pack & Deliver
Bring Back Empties
Return empty to staging area
Tuggable rack moved by tugger not truck
Monitor buffers - engineered level, FIFO
Currently use Mattec; future scan barcode?
CSF = Tugger needs to be part of IMD
CFF = No empties available
ACC = Tugger Delivery
INH = Hunting for empties

Note: Shape 12, PackDeliver

Job Instructions
Pack Defect Process To-Be
11/1/2001 To-Be Process.igx hfg
MatlHandler MatlHandler
Systems Systems
Navigation Navigation
Start Record Defect
-N
Multiple
Defects
Place in Scrap
Bin
Escalation
Process
-N
Return to
Pack
No
Yes
Return to
Level 1
Note: Shape 2, Pack Defect
Pack Defect
Record Defect
Must be simple, quick
Note: Shape 5, Pack Defect
Pack Defect
Escalation Process
Based on defined gates
Keep one sample aside for investigation
Process Control Plan Detail "To-Be"
hfg
Process Control Plans
Mold Press 1 Press 2 Press 3 Other
Condition "A"
Condition "B"
(Flash Acc.
Yellow)
Condition "C"
(Flash Needs
Trimming)
Yellow)
Condition "D"
(Do Not Use)
PCP 1 PCP 1 PCP 2 PCP 3
PCP 2 PCP 2
PCP 3 PCP 3
D.N.U. D.N.U.
To Level 1
To Set
Mold/Recipe
Certify Mold / Recipe "To-Be"
11/6/01 To-Be Process.igx hfg
Prod_Planner Prod_Planner
SPC SPC
SM SM
Proc_Engr Proc_Engr
Mold_Engr Mold_Engr
Mold_Design Mold_Design
Toolroom Toolroom
Maintenance Maintenance
Systems Systems
Navigation Navigation
Start
New Mold
Operating
Plan
1-N
Press
Capable?
2
Dave Ferron,
Toolroom,
Maintenance
3
No
Schedule
Tryout
4-N
Yes
Develop
Process
5
Run and
Identify Mold
Issues
6
Issues
7
Pull Mold
8
Fix
Mold
Issues
9
Yes
Document
Initial
Set Points
10
No
Set Limits on
Tier 1 Inputs
11-N
DOE
Develop S.M.
Adjustment
Ranges
12-N
Produce Parts
for GP-12
Evaluation
13
Verify Capable
Tier 1
Setrpoints
14
Capable
15
Adjust and
Monitor
16
No
Release Mold
for Production
18-N
Yes
Develop Tier 2
Process
Variable
Limits
17-N
Verify Limits
19-N
Certified
Recipe
20-N
Communicate
to
Manufacturing
21
Note: Shape 1, Certify
Certify Mold / Recipe
Operating Plan
Mold / Machine combination for eventual production Run
Note: Shape 4, Certify
Certify Mold / Recipe
Schedule Tryout
Tryouts are scheduled for two shifts due to process considerations (temperature stabilization)
Resources for tryout include:
Trucker
Material Handler
SPC Serviceman
Mold Engineer
Process Engineer
Set Mold in Prior Shift
Note: Shape 11, Certify
Certify Mold / Recipe
Set Limits on Tier 1 Inputs
Tier 1 Variables:
Transfer Point
Shot Size and Decompress
Back Pressure
Cycle Time
Pack Pressure and Time
Hold Pressure and Time
Cooling Time

Note: Shape 12, Certify

Certify Mold / Recipe
DOE to Develop Serviceman Adjustment Ranges
Setpoints:
Transfer Position
Hold Pressure
Hold Time
KPC
Cavity Pressure Monitoring

Note: Shape 17, Certify

Certify Mold / Recipe
Develop Tier 2 Process Variables Limits
Ensure Tier 1 Setpoints
Tier 2 Variables:
Fill Time
Injection Pressure
Screw Run
Cushion
* Not for part quality but to signal machine / mold OA issues

Note: Shape 18, Certify

Certify Mold / Recipe
Release Mold for Production
Develop Criteria
Ensure process documentation is maintained
S.M. Documents Changes to Setpoints
Note: Shape 19, Certify
Certify Mold / Recipe
Verify Limits
Updated weekly for 4 weeks
Edit data for startups and shutdowns
Note: Shape 20, Certify
Certify Mold / Recipe
Certify Recipe
Documented Setpoinjts becomes Certified Recipe
Second Underscore designates certified recipe:
Job_Tool No_Press Number
Job Packet "To-Be"
11/6/01 To-Be Process.igx hfg
SM SM
ShiftSupvr ShiftSupvr
PrevShiftSupvr PrevShiftSupvr
MatlHandler MatlHandler
SPC SPC
Systems Systems
Navigation Navigation
Plan Assign Job Preset Mold Pull Mold Run / Pack
Return to
Level 1
Daily Plan
Pull / Prep
Job Packets
for Next Shift
1-N
Organize
Finalize
Job Packets
2-N
Distribute
Job
Packets
3-N
Stage & Kit
Mold
4-N
Setup
Workstation
5-N
Pull /
Set /
Start /
Stop
6-N
Run
Job
&
Maintain
Run
Log
7-N
Return
Job
Packet
8-N
Close Out
Job Packet
9-N
Job Packet
Library
Job Packet
Archive
Recipe
Database
Note: Shape 1, JobPacket
Job Packet Process
Pull / Prep Job Packets for Next Shift
Previous shift supervisor pulls job packets for next shift per daily plan
Note: Shape 2, JobPacket
Job Packet Process
Organize / Finalize Job Packets
Supervisor gets packets from previous shift supervisor and makes assignments
Note: Shape 3, JobPacket
Job Packet Process
Distribute Job Packets
Supervisor distributes job packets to S.M. and Material Handler/HVAC
Note: Shape 4, JobPacket
Job Packet Process
Stage & Kit Mold
Serviceman uses job packet (kitting instruction) to stage & kit mold
Note: Shape 5, JobPacket
Job Packet Process
Setup Workstation
Material Handler or HVAC uses job packet to set up workstation
Note: Shape 6, JobPacket
Job Packet Process
Pull / Set / Start / Stop
Serviceman uses job packet to set up mold
Material Handler / HVAC returns job packet information to Serviceman
Serviceman exchanges job packets at press:
Old/Complete < -- > Current/Active
Serviceman return completed job packet to supervisor after starting current job

Note: Shape 7, JobPacket

Job Packet Process
Run Job & Maintain Run Log
Serviceman records significant events on run log (posted at press)
Note: Shape 8, JobPacket
Job Packet Process
Return Job Packet
Supervisor must check to ensure packet is complete, in order
Resolve open issues (refer to run log)
Supervisor returns job packet to SPC

Note: Shape 9, JobPacket

Job Packet Process
Close-out Job Packet
SPC reviews job packet completeness
SPC removes completed setup sheet with run log, makes copy, archives original
SPC prints out new setup sheet, staples copy of previous setup/run log sheet and places in job packet
SPC inserts new pull/set/start/stop checklist into job packet
SPC returns job packet to library (must be ready for use at next job run)
Size of archive TBD (3, 6, ?? months)

IM Lean Job Execution Process Improvement Workshop

11/6/2001 Page 1 hfg
LEAN Considerations
Teams 3,4: Operational Availability
Chart 1: Plan IM Production
Need overall OA training across the board
Yield per certified mold/press combination
Scrap losses (IM & Assembly)
Setup time
Manpower Availability
Press availability
PM Planned downtime
Repair maintenance Hours
Valid recipe
Chart 2:
Assign Job
DMS Owner-operator concept, include trades
Actual manpower availability
Set Mold/Recipe
Improve setup time
PMs
Training for Serviceman
Troubleshooting
Setup
Quality checks
Mold set teams familiar with jobs, dedicated to mold set, not also running presses
Resources / Restructure (SM)
Chart 3:
Start/Run Job
Quality process to eliminate bad parts
Running PMs
SM, Trades
Call Process for quick response SM/Trades
Log/Report Maintenance Repair Time
Spare Parts Availability
Trades Availability right number of needed trades, representatives on IM team
Run to the Plan LEAN no over-runs
Chart 4:
Pack & Deliver
Dunnage (Racks, Carts) available
Purchased parts available
Manpower available (Truckers, MH / HVAC)
Production Reporting
Data collection
Communication process and system between MH/HVAC
Quality Gates / Escalation Process
Feed back performance to operating plan
IM Lean Job Execution Process Improvement Workshop
11/6/2001 Page 1 hfg
LEAN Considerations - 3pm to 4:30pm
Report-out 4:30pm 6pm
Teams 1,2: Material
Chart 1:
Plan
Level Schedule
Raw Material Pellets
20% TFPP
40% TFPP
20% GFPP
33% GFPP
HCPP
Inside Silos
Drying Temperature
Moisture Check
Efficiency of Drying System - PM
T/C Check
Plugged Air Holes
Investigate Dessicant Dryers
Air Filters
Outside Silos
Sucks air in
Dryness of air intake
Cleanliness
Keep Doors Closed
Purchased Parts
Sub Assembly Components
PC&L
Pull System
Molds
Ensure adequate number for volume of part number
OA & Not Cost
Buffer Status will determine schedule
Chart 2:
Assign
Packet
Defines what material needed
Bill of Material for sub assembly
Purchased Parts
Verify Presence of parts at workstation
Set Mold / Recipe
Packet
Kit
Crane box
Ensure mold in area
Chart 3:
Start/Run
IM Lean Job Execution Process Improvement Workshop
11/6/2001 Page 2 hfg
PPE, Mold Spray, etc
Pack containers / cardboard
Inspection gages and checklist
Movable cart takes inspection to part/machine, spend less time walking
Packet
Turn hopper on to fill hopper with right plastic pellets
Chiller water
Process water
Compressed air
Electricity
Mold accessories:
Valvegates
MSI
Operational molding machine
ID Tags
Movable cart
Chart 4:
Pack & Deliver
Packet (Pack Diagram)
Pack container / cardboard / ID tags / tuggable carts
Molded part / sub assembly with purchased parts
Conveying system belts
Truck / tugger / Creform rack
Buffer status / management
Barcoding every rack sent and removed from buffer
ID tags
Throwable / disposable
Programmable Tag Printer
ID tag system disposable printed at workstation
Discussion
Scan standard pack / rack (internal paypoint) keep track of buffer
However concept of LEAN engineered buffer and tuggers = exact number of parts
Always know min/max in process without coding visual controls to see inventory
Added to flipchart photo: Tugger/Trucker visually determining buffer
IM Lean Job Execution Process Improvement Workshop
11/6/2001 Page 1 hfg
LEAN Considerations - 3pm to 4:30pm
Report-out 4:30pm 6pm
Team 6: Quality
Chart 1:
Objective: Not to run bad parts
ICA Irreversible Corrective Actions
Pre-launch PCP
Normal PCP
FTTQ Data to drive ICA
QIP Team owners of ICA
Escalation process
Plan to handle non-conforming parts
Responsibility for acceptance
Rules of running to mold process
Plan to reduce the number of 1000 ton open loop presses
Plan to reduce the number of small presses
Chart 2:
Roles defined
Serviceman
Maintain process
Time-based inspection
Machine PMs
Inspect part for physical damage, B.C.P.
Process - Mattec Parameters
Material Handler / HVAC Relief
Verify part integrity
Review assembly process job instructions, material ID
Time-based inspection relief
Maintain quality boards, communication
Material Handler
Pack and inspect parts per job instructions
First / Last part inspection for plastic parts
Add content per JI
Floor Inspector
Verify Serviceman process checks
Verify relief operator process checks
Monitor Mattec process control
Escalate out of control process
Monitor recipe
First piece check
SPC
Process validation and certification
Trades
Part of Team
Discussion
IM Lean Job Execution Process Improvement Workshop
11/6/2001 Page 2 hfg
Recipe validation on a continuing basis capture verification process
(under Floor Inspector)
Monitor mold/machine output triggers
Process triggers are set points that dont change
Minimum CpK 1.33 drive up 10 sigma
Need to define a good part tolerances, flash, serviceability, fit/form/function (part print)
Define acceptability (when defect {flash} is acceptable)
Run operation based on acceptable performance criteria
Chart 3:
Escalation process
Material Handler: If 5 parts / hour, notify Serviceman
Serviceman: If 5 parts / 2 hours or 10 parts / hour, notify Supervisor
Notify Process / SPC
Supervisor: Notify Quality / Next level manager
Problem
Corrected
Need Parts
Evaluate Need
Continue Run
Plan Qty
Hold Part
- Deviation Instruction
- Approval
- Verification
Shut Down
& Repair
No
Yes
Yes
No
Chart 4:
New Parts coming in
Use Mattec?
Controls established
PFMEA
PFD
Pre-launch PCP
Meet GP-12 requirements obtain exit criteria
Move to part-specific PCP
Scrap
FTTQ: System to have data on OA issues
QIP Team Drive Corrective Action
Improve Process Capability
Quality, manufacturing engineering, engineering
Discussion of need / advisability to get rid of excess machines:
View 1: Keep but upgrade to process capable
IM Lean Job Execution Process Improvement Workshop
11/6/2001 Page 3 hfg
View 2: Eliminate excess machines that absorb OA resources without providing production
capacity; go to 3-shift flat schedule on better machines run at optimum utilization
Beneficial Attributes / Enablers
1. Decoupled Molds
Separates mold from press; by decoupling, monitor mold conditions (DOE) to generate
template curves. Transportable from press to press by matching mold curve.
Validate and PPAP once
Install pressure transducers
DOE
Education
Tie into Mattec
2. Recipe Level Qualification
Qualify: Serviceman
Validate: SPC
Certify: Another level of (Phase III) process engineering protocol to establish UCL LCL
3. Job Packet
Electrical diagrams
Water diagrams
Pin diagrams
Pre-staged kit contents, (any pertinent information)
4. Accountability to run prescribed recipes, collect reasons for deviations
Andon, HMI, Visual Controls
5. Electronic on-line storage
Packet and Recipe (PDM Data Integrity)
Include ownership to ensure up-to-date / accuracy, current data
6. Ability to locate
Tools
Job packets
Kits pre-staged
7. Standardization
Standard way to work, including all elements:
Workplace organization
Kits/locations
Mold trackability
Tool Room storage
Beneficial Attributes / Enablers
8. Mold inventory
Physical mold storage areas allocated
Staging System
Equip mold with legs to decrease storage requirements for racks; safer to hook to
crane (no standing on racks)
Mold Standards
9. Consistent Operating plan
Limits on press/mold combinations
Optimize physical combinations
10. Education / Training
Training / education on equipment, process, systems; and documentation
IM Lean Job Execution Process Improvement Workshop
11/1/2001 Page 1 hfg
Pack & Deliver Discussion
Pack and Deliver
Team 2
Chart 1: Overall Flow
Receive Parts
Visual Check
Add Content
Pack Part
Move Packs
Monitor Buffer
Chart 2:
Receive Part
Receive Part MH/HVAC
Pick Up Parts MH/HVAC
Monitor Flow MH/HVAC (Parts continue to flow)
Do not sort start-up parts
Index Belt and conveyor: incrementally move, give part cooling time
Pace conveyor to press
How to reduce jamups and reduce scrap?
Belts slipping, parts sliding on belt
PM plan, design plan for conveyors, and have trades part of team
Sensors at workstations to signal parts back-up - alarms
Visual Check (not inspection)
Visual aids at workstation
Scrap reporting / data collection
Need mechanism to measure and refine first-time quality
Detailed visual check
First part in rack
Short shots, flash, screw bosses, oil
During rack pack, know key features for visual checks
Detail visual check on last part in rack
Chart 3:
Add Content
Flex hinge - subassemblies
Trim/condition if required: not at workstation, need instructions, approval,
verification, safety is issue
This is a violation of PPAP if unapproved
Sub-assemble need detailed job instructions, parts and sequence
Chart 4:
Pack Part
Correct racks
Check for/fix rack damage
Follow pack instructions (available, easy to understand)
ID with correct tagging
IM Lean Job Execution Process Improvement Workshop
11/1/2001 Page 2 hfg
Move Packs
Tuggable rack operator moves to staging area by material handler
Pull packs (racks?) when full
Replace empties
Deliver to proper location
Return empty to staging
Tuggable racks are moved by tugger not trucker
CSF: Tugger operators need to work for IM not PC&L (material management)
Chart 5:
Monitor Buffers
Engineered levels
FIFO is desired
Currently use Mattec, future scan part?
Two additional charts to capture original thoughts
Charts 6:
Visual aids animated visuals
Clean garbage from racks
Correct racks tuggable set-up
Packet what is planned to run
ID of packs define location
Subassembly content have purchased parts at workstation (On Pull should be there)
Job Instructions
Error-proofing
Process starting part / workstation
Visual check by operator
Swifting of bad parts
Changing racks when full during run
Charts 7:
Truck availability
Cleaning dunnage / junk from racks
Need for cardboard
Method of Rack ID
Swift of Start-up parts
Know status of start-up prevent start-up parts from reaching workstation
Team 1
Chart 1:
Pack & Deliver
JIs read and understood
Workstation setup for tugging
Parts damaged when ejected / dropped onto nets
Use pick-and-place?
Some conveyors too steep
Parts damaged at jam-up
Communication board at each station
Floor inspector focus is to monitor process
Remove old tags, replace new tag
IM Lean Job Execution Process Improvement Workshop
11/1/2001 Page 3 hfg
Error proofing ideas - overall audit of conveying system, PM plan and
implementation
Chart 2: A Detail
Record defect (touch pad, etc)
Gate process based on number of pieces/defects leading to escalation, containment
processes
Chart 3: B is continuation of chart 1
Future state wants to arrange workstation to allow use of tuggers to replace fork
trucks
Consistent method of signaling for fork trucks (flags?)
Use roller conveyors to bridge time when material is removed and empty racks not in
place
Diagram: Split presses into banks of 2 (instead of current 4); pre-staged Creform, indexed
conveyors, pick and place.
Discussion of current situation:
Mold sets go off of physical inventory counts
Planner schedules a mold to run until needed quantity of good parts is obtained.
Supervisors (not planner) schedules presses to run, presses run until desired quantity of good parts is
obtained.
No count of scrap.
No yield data for mold/press data.
Mattec gives you number of blows (cycles), not good/bad.
Lunch Break
Break into small groups, address ACC, INH, CSF front to back
Job instructions
Packets
Mold/Press certifications