Improving Ultra•Seal process to cut time and costs

Assembly Team Leader, Ian Boquiron, and his team were set a task and budget to cut costs and reduce the standard time in Ultra•Seal by 50%.

The team started the project by mapping out the current state, and measuring and collecting data.

The team then reviewed the waste to decide what could be reduced or removed.

Creating a new layout with the improved techniques, the outcome of the future state reduced the process time from 52 minutes to 34 minutes.

To reduce standard process times, the following changes were made: changing the layout of the cell and the process flow; removing some processes that were no longer required; testing charge airs on the press; reduce distance traveled; combine some of the processes; and remove manual processes by introducing new tools.