Up Time Magazine- August/September 2008

Transformational Analysis DEFINE Known Problem Or Value System Mapping (VSM) (Baseline) PR Plots & Process Modeling MEASURE Create Process Improvement Team (PIT) Educate PIT Team Videotape Processes in the Field ANALYZE Identify Physical Work Steps (Include Time) Identify Internal & External Steps & Waste IMPROVE STEP 1: Convert Internal Steps To External n Kaize Meth ods STEP 1: Eliminate Waste STEP 5: Measure and Adjust New Process STEP 3: Improve Reliability of Internal Steps YOU ARE HERE Sustain the Gains. Document New Process Train to New Process Audit/ Monitor Continually STEP 4: Improve Reliability of External Steps DEFINE Figure 9 - Transformational Analysis Approach proach that she attended workshops to learn how to utilize some of the improvement tools to help her develop a business level improvement plan. The scope of this plan focused to deliver at least 75% of the identified loss potential previously identified. The design of the workshops included representatives from all five plants to encourage increased leveraging and quick implementation of ideas that were beneficial to multiple sites. After conducting the workshops, the business level improvement plan incorporated into the results are shown in Figure 10. The results of this work quickly helped the “ABC” Business Leadership Team to set clear direction for the capacity growth and priority for the entire company. They decided to: 1. Engage the Service Provider to help the improvement teams to fast track top priority items identified from the workshops. 2. Defer any plans to invest in building a new production line. 3. Deploy a small team to complete a more detailed acquisition study of the competitor’s facility and consider if the current “ABC” improvement plan would minimize the safety, environmental or economic risks of purchasing this facility. This would defer acquisition of the competitor’s facility until at least 2010. 4. Focus Engineering Team to complete the Front End Loading for a new production line within the next year. The analysis in Table 1 can be translated into a simple table of current performance against future performance as measured by OEE, these OEE figures and losses being adapted from the Barringer Charts above to more accurately reflect maximum demonstrated sustainable rate. Note that the increase in output is anticipated to be 106,000, going from 236,000 tons per year to 500 450 400 350 “ABC” Company 2011 Capacity Utilization = 96% Capital Investment = $50MM New Capacities Based on 75% of Identified Potential Extreme Pinch-point before 2012! Rated Design Capacity - 370 M Tons 300 250 200 150 100 50 0 2007A Turkey Creek Big Bend 2008 2009 Marsh Point Red River 2010 2011 Eagle Cliff 2012 90% - Forecast Annual Growth Figure 10 - Capacity Utilization for ABC Company august/september 2008 http://www.timken.com

Table of Contents Feed for the Digital Edition of Up Time Magazine- August/September 2008

Up Time Magazine- August/September 2008 Contents Upfront Upclose Information Technology Lubrication Infrared Maintenance Management Motor Testing Precision Maintenance Reliability Ultrasound Vibration Upgrade

For optimal viewing of this digital publication, please enable JavaScript and then refresh the page. If you would like to try to load the digital publication without using Flash Player detection, please click here.