Improving Process Efficiency Lou-Rich, Inc. Carter Tollefson Advisor: Jon Vanyo Company Supervisor: Lee Gulbrandson
Company Overview • Contract engineering and manufacturing • Based in Albert Lea, MN • Provides services to original equipment manufacturers (OEMs) in ag., medical device, food service, and many more • Services include: engineering design for manufacturing services, material sourcing, welding, assembling, testing, CNC machining, fabrication, powder/liquid coatings, assembly, aluminum extrusions
Albert Lea
Process Description • 5 different freezers made – all follow similar processes • Components (coils, flanges, and tubes) made
Process Continued • Washed • Welding tube and flange
Process Continued • Soldering coil to tube • *Base and inlet welding
Process Continued • Machining Processes • Foaming
Incentives to Change • Commitment to process improvement • Investigate process efficiency opportunities • Source reduction opportunities in washing system
Reasons for MnTAP Assistance • Investigate/implement lean opportunities • Look for opportunities to improve operator processes • Determine opportunities for chemical and water savings • Reduction of inventory in work cells
Approach • Monitored and gained understanding of processes • Documented own ideas for improvement • Held brainstorming sessions and documented ideas for improvement • Identified the types of waste and where is it was occurring
Determining Solutions • Timed processes • Value-stream maps • Spaghetti diagrams • Consulting with companies • Reviewed observations and notes • Meetings with staff and operators
Current Layout and Part Movement • Opportunities • Excess movement taking parts to and from work cells • Loading time onto carts and machines • Solutions • Implement conveyor system between work cells • Change equipment orientation and locations • Savings • ~260 hrs/year $7,100/year
Washer Location Power Water Pump Resistance Solder Coil Coil Tube Super Long Short Super Short Old Relic Work Tubes Tubes Tubes Tubes Superma Tubes Water SS SS Marke Coils Coils Marke Coils Bench Heater SS SS SS rket Freezer Freezer t t Freezer Freezer Freezer Post Cart Cart Coil Copper Tube Rack Cart Cart Cart Electrical Cure Oven Rack Rack Chip Hopper Packaging Supplies OEC Storage Rack for Foam Electrical Fan Foam Dies Copper Coil Straightener Tubes Unload Table Chip Hopper Raw Saw Electrical Brake Pad Cut Tubes Assembly Boxes For OEC Shipping Cleaning Elec Panel Station Freezer Rack Conveyor Unload Bay Table Freezer Rack Load Bay Boxes For Freezer Rack Freezer Rack Shipping SS Tank Freezer Tubes with Freezer Tank Tank Tank Vent & Packaging Supplies Table Cart Heat SS Rack Work Bench Freezer Burnisher Bench Work In Feed Table Small Parts Work Bench Drilling Station Cart Flange Superma Drai Base Solder Station Natco DP Raw SS rket n Cart Bench Profilometer 8 Hole Work Burnisher Conveyor Grat Rinses Drain Freezer Rack Freezer Rack Bench Work Long e Inspection Washer Counter Coils Cart Cardboard Rack Sink DP Elec Panel Test Tank Table Tig Tig Superma Nitro Tank Rack Water Leak S Station Welder Foamer e r Tester r a rket Work Bench Gas Tanks t e T a p Fixtures r D P Spout DP Debur Base Cone Station Foamer yor er Sink Count Flange Freezer Rack Chip Hopper Rack Pack Out Table OEC Cart OEC Cart OEC Cart OEC Cart OEC Cart Panel Elec Foamer Fluxer Solder Tank HOOK COVERAGE ON HOIST HOOK COVERAGE ON HOIST Station Pump Foamer Foamer Foamer Inline Tool Electrical Solder Rinse Cabinet Washer Washer Rinse Rinse Prepare Rinse Soap Cabinet Chest Welding Fluid Heated Raw SS Cart Tool Tanks Fixtures Solder Tank Tank Tank Tank Tank Chest Water Main Tank Cabinet Torch Mounts Panel Venting and Plumbing for tanks Hooks Hooks Bubble Foam Scale 16 Cabinet Supply WASHER OK to Ship Incoming Lane
Current Layout Power Water Pump Resistance Solder Coil Coil Tube Old Relic Work Super Long Short Super Short Water Tubes Tubes Tubes Tubes Superma Tubes SS SS Bench Heater Marke Coils Marke Coils Coils SS SS SS rket Freezer Freezer t t Freezer Freezer Freezer Post Cart Cart Coil Copper Tube Rack Cart Cart Cart Cure Oven Electrical Rack Rack Packaging Supplies Chip Hopper OEC Storage Rack for Foam Electrical Fan Copper Coil Straightener Foam Dies Tubes Unload Table Chip Hopper Brake Pad Raw Saw Electrical Cut Tubes Assembly OEC Boxes For Elec Panel Shipping Cleaning Station Freezer Rack Conveyor Freezer Rack Table Boxes For Freezer Rack Freezer Rack Shipping Tank SS Freezer Tubes with Freezer Tank Tank Tank Packaging Supplies Table Vent & Cart Heat SS Work Bench Burnisher Bench Freezer Work Small Drilling Station In Feed Table Parts Work Bench Cart Superma Flange Drai Solder Station Natco DP Base Raw SS rket Profilometer n Cart 8 Hole Bench Work Conveyor Rinses Burnisher Bench Grat Drain Freezer Rack Freezer Rack Work Long e Inspection Washer Cart Counter Coils Test Table Sink DP Tig Tig Elec Panel Tank Nitro Tank Rack Water Leak S Superma Station Welder e Foamer r Tester r rket Gas Tanks a Work Bench t T a Fixtures e p Spout DP r D P Debur Base Cone Station er Sink yor Count Foamer Flange Freezer Rack Chip Hopper Panel Elec Foamer Fluxer Solder Tank Foamer Foamer Foamer Station Pump Inline Electrical Tool Solder Rinse Washer Cabinet Cabinet Welding Washer Rinse Rinse Prepare Rinse Soap Chest Cart Fluid Heated Raw SS Tool Tanks Fixtures Solder Tank Tank Tank Tank Tank Water Main Tank Cabinet Chest Torch Mounts Venting and Plumbing for tanks Panel
Proposed Layout Proposed Scotsman Layout Power Water Pump Copper Tube Rack Unload Table Straightener Copper Coil Water Welder Water Leak Panel Heater Conve Elec Tig Tester Torch Fixtures Welding yor Cabinet Cabinet Post Electrical Tanks Coil Washer Electrical Coil Foamer Chip Hopper Station Rack Rack Solder Chip Hopper Tig Station Inline Foamer Fluxer Freezer Rack Conveyor Packaging Supplies Electrical Packaging Supplies Work Bench Conveyor Tank Work Bench Elec Panel with Tank Tank Tank Move Vent & Conveyor Tubes Heat able Coils Foamer Small Parts Table Double Conveyor with Bases and Burnisher Work Bench Solder Station Cart Flanges Cleaning Raw Saw Raw Saw Station Natco DP Profilometer Foamer 8 Hole Cut Tubes Cut Tubes Bench Work Two way-Conveyor In Feed Table Flanges + Foamer Cart Bases Burnisher Counter Grat Drilling Station Sink DP e Drain Bench Work Fixtures Boxes For Gas Tanks Serrater Shipping Inspection Debur Station Tap DP Table Spout DP C e r o Boxes For S u Test Rack n Tank Shipping i n Rinses t Nitro k Tank Work Bench Chip Hopper U-Shaped Washer Short Coils Raw SS Rinser Walkway Tool Chest Foamer Electrical Panel Elec Solder Tank Rinse Pump Rinse Rinse Prepare Rinse Soap Heated Tank Tank Tank Tank Tank Raw SS Water Main Tank Storage Rack for Foam Solder Tool Tool Tool Foam Dies Cabinet Cabinet Cabinet Cabinet Tubes Mounts Chest Panel Venting and Plumbing for tanks Chest Chest
Spaghetti Diagrams Proposed Movement Current Movement
Coiling and Foaming Processes • Opportunities • Inventory build up between process steps (non value adding time) • Excess inventory • Waiting • Order of operations efficiency • Solutions • Creation of standard work documents • Training and explanation to operators • Savings • ~420 hrs/year $11,500/year
Current State Part Washing Process • Coil Washer • Not performing up to washing standards • Chemical and water go straight to drain after one cycle • Hallway Washer • Wash, Rinse, Blow off • Operators paid to load and unload parts • Parts from different areas washed in same washer
Proposed Improvements • Remove coil washer • Power, water, and chemical savings • No chemical and water being wasted • Purchase New Washer and Place in Freezer Area • Dual-rinse and overflow system to conserve water and reduce operator attention • U-shaped design • Current operators will be reassigned • No waiting for non-freezer parts • Elimination of forklifts and operator time transporting parts
Improvement Savings • Savings Coil Washer • ~1,270 kWh/year $100/year • ~19,200 gal/year $120/year • Chemicals - 866 gal/year $13,000/year New Washer • ~280 hrs/year $7,700/year • ~29,300 gal/year $180/year • Not using forklifts $1,750/year • Not paying operators $2,550/year
Part and Finished Product Storage • Opportunity • Large amount of inventory between work cells (space, $) • Trouble adjusting to order fluctuations (change-overs, shipping dates, part moving and storage) • Distance and time to bring components needed to assembly areas • Solution • Install finished goods supermarket (buffer for changes) • Part supermarket (ordered and proximity to cells) • Pull system based on demand rather than push based on predictions • Savings • ~50 hrs/year $1,400/year
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