Pilar Kobetsu Kaizen (Focused Improvement) Pillar I : Focused Improvement Objectives Maximizing the performance of equipment by minimizing losses of equipment Problem Solving by GROUPS Compare the ACTUAL operating time versus the OPTIMUM operating time Highlight the causes of Productivity losses : Availability, Performance and Quality losses Improvement Steps Define Losses 2 Quantify Losses Analyze Causes Generate Countermeasures Implementation Follow up Available Time = 100 % OEE Downtime 1. Equipment Stop Loss Pallet Jams, Silo stops, Slide Gate, etc Operating Time 2. Set up/Adjustment Loss Sensor Dirty / Off, Adjust Former height, etc Net Operating Time Performance 3. Parts Change Out Leaky cylinder, Change Over Loss, Wait System, 4. Start Up Loss Change Overs, Not ready at 4AM,12 Noon, 8PM 5. Minor Stoppage Loss Lack of *** Dribbler adjustments, Bags jamming Valued Operating Time = 25 % OEE 43 Quality 6. Speed Loss Run Rate, Machine Speed – Conveyor Belts, Dribbler,etc Wasted$$’s 7. Defect/Rework Loss Bad formula, Wrong ingredients, On hold, etc