P09457: Process Improvement Project
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Weld Booth

Table of Contents

Weld Booth Layout

Primary Needs

Secondary Needs

Suggested Changes

Risks & Contingencies

Risks and Contingencies
Risk Severity Probability Owner Status and/or Contingency Plans
Worker resistance to change High High Team/ Dave Couple of workers will complain as their "luxuries" may be taken away, overall changes are minor
Uniform weld booth eliminates ability to do some jobs Low Low Team Since the weld booths will be paired and composed of curtains, one weld booth can easily become two to work on bigger pieces of pipe
Operator differences in operating hand (left handed vs. right handed) Medium Medium Eric Currently there is only one left handed operator and his weld table is positioned in the left hand corner of the booth. Items within booths should reach tables if positioned in either corner

Layout

Standard Weld Booth Layout

Standard Weld Booth Layout

Weld Curtain Options

Concept 1

Concept 1

Concept 2

Concept 2

Concept 3

Concept 3

Results

Elimination of Argon Cylinders

Install visual control system

Simple exhaust system

Rollers For Every Weld Booth

New Weld Curtains

Weld Stick Rod Kaizen

Current State

Kaizen Event Plan and Target Sheet

Current State Weld Stick Checkout Flow Chart

Current State Weld Stick Checkout Flow Chart

Brainstorming

Expanding Brainstorming Ideas

KANBAN Card System

Place certain amount of weld rod tubes in to large bag with Kanban card in bag. When individual opens bag, Kanban card is removed and brought to specified location so an order can be placed.

Visual Control System with One Individual in Charge of Ordering

Develop a storage mechanism for weld rod tubes and color code minimum levels on storage mechanism so when weld rod tubes go below this specified level it is visually known to order more tubes. One person will be in charge of checking weld rod tubes levels daily and placing orders when necessary.

Lock Box System

Create two storage locations for each weld rod tubes. Set quantities in each box is predetermined. One box will be unlocked constantly and the other will be locked. When unlocked box is emptied, the individual who seeks a weld rod tube finds the person with the key to unlock the other box. The unlocking of the box triggers the key master to order more weld rods.

Vendor Managed Inventory System

Have the supplier check weld rod tubes on a weekly basis and constantly fill weld stick rods to maximum levels.

Future State

Future State Weld Stick Checkout Flow Chart

Future State Weld Stick Checkout Flow Chart

Storage Mechanism

Storage Device Front View

Storage Device Front View

Storage Device 3D

Storage Device 3D

Note: Storage devices pictured does not reflect actual storage devices as these are just concepts.

Benefits

Moving Forward

Kaizens

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