Apply the E.C.R.S.

technique and identify improvement

actions: mechanise some movements
Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

ISW ISW
Before E C R S After
OSW OSW

Problem: Difficulty in changing the drum height Improvement: Pneumatic system to lift the drum up

Results: It is possible to change the drum height rapidly and without physical efforts

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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -1-

 Apply the E.C.R.S. technique and identify improvement
actions: rapid clamps
Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

stop
stop

mould

Pressure
closing
system

Reduction of the number of parts for a single screw-less mould

change
Problem: the mould change requires unscrewing 6 bolts Improvement: two stops and a pressure closing system simplify
the operation
Results: the mould change takes 5 minutes less

Training date - - - - - - - -

Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -2-

 Apply the E.C.R.S. technique and identify improvement
actions: rapid centring systems
Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

U-shaped slot

shape
shape

base base
Problem: to change the shape it is necessary to unscrew and Improvement: A U shape slot allows changing the shape
remove the bolt that connects it to the first base by simply loosening the tightening bolt
Results: The set- up time takes one minute less per bolt
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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -3-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

E C R S
Slacken by means of a 6-mm Allen wrench
the two fixing screws of the first roll on the
left so much so as to lift by 2-3 mm and to
remove the support of the roll from the
slot, pushing the support itself backwards.

Insert the screws of the roll supports into

the slots and pull towards oneself until the
fork support is inserted. Tighten the
screws and repeat the operations
described for all the rolls (except for the
central one which is fixed)

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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -4-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

I wish I had another pair of hands Well, this is very handy!

Problem: Awkward equipment changes Improvement: Band fitted to retain machine parts

Results: Reduced set-up time, elimination of tools, accurate setting

Training date - - - - - - - -

Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -5-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

chuck chuck

Problem: Head alignment in an uncomfortable position behind the Improvement: Blocking position more comfortable and manual steering
machine (spanner needed) wheels mounted (no spanner needed)
Results: Set-up time reduction
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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -6-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After
Size check
Size check
Position square

Max gap 1,5 mm

Check that the two ends Check of the gap 1,5 mm Graduated line
are at the same level
Meter Meter

Problem: Need for two checks: Size check of the U-bent resistances and Improvement: Checks facilitated
check of ends’ level
Results: Adjustment and retrieval time reduction

Training date - - - - - - - -

Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -7-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Cup Stake of ABC 3755/7 - 5 type

Hexagonal spanner
Grain
Cone
Extraction

New cone

Problem: To replace the cutting cone it is necessary to unscrew two Improvement: To replace the cutting cone, one just has to lift the
grains. Time waste because the screws are hidden and in an detachment stake and to extract the cone without using any tools
uncomfortable position
Results: Set-up time reduced from 80 sec. to 10 sec. and lower cone building costs (for minor works)
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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -8-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Insert (new)

New main block

Insert
Ray closing mould
Screw
Main block

Problem: To replace the insert of the main block, it is necessary to Improvement: To replace the insert of the main block one just has to
remove the ray closing mould and to unscrew the screw by means of a extract it from its seat without any tool and without taking the ray
spanner closing mould out
Results: Set-up time reduced from 180 sec. to 10 sec
Training date - - - - - - - -

Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 -9-

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Adjustable retainer

To remove
To insert

Ball grain
Letter-holder
Letter-holder slides
Problem: To replace the letter-holder, it is necessary to move the Improvement: Slides replaced and letter-holder mounted on a new one
retainer, to extract the letter-holder, to insert a new one and to move the with ball grains. To replace the letter-holder, just lift it up and rotate slightly
retainer forth
Results: Set-up time to replace the letter-holder reduced from 20 sec to 5 sec
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Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 - 10 -

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Problem: Device adjusted by trial and error Improvement: Handles and counters mounted

Results: Adjustment time reduction

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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 - 11 -

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Problem: Too much time to fix the ring Improvement: Fixing hole modified

Results: Reduction of the replacement time

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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 - 12 -

 ECRS_S - Opl

Plant:
One Point Lesson (OPL) WCOM™

Basic Knowledge Problem Improvement N°

Filled by: Date:

Before E C R S After

Problem: Too much time to change position Improvement: Pneumatic screwdriver adopted

Results: Reduction in the time to replace positions

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Trainer - - - - - - - -

Trainee - - - - - - - -

Opl ECRS_S Solving Efeso © 1999 - 13 -