Table of Contents
Weld Booth Layout
- Improve Safety
- Standardize weld booth
- Better use of space by eliminating unnecessary equipment/materials
- Allow welders the flexibility of using any weld booth
- Install visual controls to ensure welder is always busy
- Construct exhaust system to remove gasses generated from welding
- Make continuous improvements as necessary
- Eliminate the need for tools to be borrowed
- Standardized Weld booth
- Eliminate argon tanks
- Dig trenches for cords
- Install visual control
- Make pipe-fitters aware of when/which welder needs work
- Make pipe-fitters aware of when welder has completed work
- Simple exhaust system
Risks & 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|
Weld Curtain Options
Elimination of Argon Cylinders
- Argon tanks are being removed from each individual weld booth with the inclusion of one large argon tank located outside. Argon will be piped to each weld station.
- Eliminates the need to manually handle cylinders (150 lbs). As a result strains and sprains, number 1 injury at Olean, will be reduced.
- Prevents the possibility of a gas leak from tipping, dragging, sliding, rolling or laying of the cylinders.
- Eliminates the need to refill portable tanks (currently approximately twice a week) as well as decrease clutter in weld booths.
Install visual control system
- With the addition of colored lights, pipe-fitters will be aware of when/which welder needs work
- Pipe-fitters will also be aware of when the welders have completed work to be picked up
Simple exhaust system
- By adding an oscillating fan along each column, hazardous fumes are drawn from the welding booths allowing workers to leave curtains closed
Rollers For Every Weld Booth
- Without rollers, workers need to rig together some sort of mechanism to hold bigger pieces of pipe. A purchased roller will be safer then something created by the welder.
- As a result of adding a roller to each weld booth, setup time and process time are both decreased.
New Weld Curtains
- Argon gas is heavier then air and will therefore settle in the weld booths. *Lifting the weld curtains a foot off the ground will provide better ventilation.
Weld Stick Rod Kaizen
- 1 Person in charge, daily visual checks
- Check every booth daily
- Set some sort of reorder point, KANBAN
- Visual Control system
- Lock up weld rods
- No central storage, reorder from booth
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.
Note: Storage devices pictured does not reflect actual storage devices as these are just concepts.
- Quick, visual way to identify what needs to be ordered
- Responsibility falls in one individuals hands
- With correct buffer and safety stocks, weld sticks will never run out
- Reduced number of weld sticks on hand
- Determine minimum quantities (Pat Comer)
- Determine reorder quantities (Pat Comer)
- Identify employee to check weld stick quantities (Dave Thompson)
- Build storage mechanism (Dan Krenn)