Business Process Lean

• Asheboro Plant
“18”-"24” Rationalization

Revision 11/29/01 ©2001 The Timken Company 1

Instancing Process Kaizen Event
Instancing is the process by which new part number-inspection code
information is entered into Asheboro’s manufacturing databases and
verified for production. It includes:

Transferring part-specific information from Corporate databases to

Asheboro databases
Verifying all the inputs have been transferred and that they are
correct
Running ICAD models to ensure product does not violate
manufacturing rules
Creating work instructions for the shop floor
Procuring any needed tooling
Coding the item as orderable

©2001 The Timken Company 2

Instancing Process Kaizen Event
Objectives:

•Reduce individual task times below Takt time

•Decrease average instancing flow time by 15% (based
on time to complete once job leaves queue)
•Develop understanding of Lean concepts
•Takt Time, Flow, Kaizen, Pull, Value Stream, etc.
•Obtain buy-in from those not involved with the event
•Implement changes by end of the week (One month max)

©2001 The Timken Company 3

 Instancing Process Kaizen Event
Baseline:
Instancing Process - Task time vs Takt time chart

Obtain dimensional data 30

Check for roller 5

Obtain insp codes & assy no's. 60

Check code requirements 30

Make sourcing decision 10

Send request to MSI team 10

Critical Path Tasks

ASB Capability Analysis 18

Load queue 35

Load data in ASB databases 307

Forging design 90

Verify inputs vs. outputs 120

Procure tooling 52

ICAD verification 90

ICAD error correction 23

Code as orderable 11
Takt time
0 50 100 150 200 250 300 350
Duration (Minutes)

©2001 The Timken Company 4

Instancing Process Kaizen Event
Method:
•Defined current process using a process map
•Map shows timing, duration, inputs, outputs, & responsibility
for tasks
•Evaluated each task in terms of value to customer
•Envisioned and defined the ideal process
•Eliminated non-value added activities that are not necessary and
minimized those that are necessary
•Attacked all forms of waste
•Constructed two new processes based on the value-added steps
of the current process and the future vision
•Developed action plan to achieve the Phase I process
•Next: Determine how to control the process and regulate its flow
©2001 The Timken Company 5
 Instancing Process Kaizen Event
Results:
Instancing Process - Task time vs Takt time chart

Obtain dim ensional data 30

Check for roller 5

Obtain insp codes & assy no's. 5 55

Check code requirem ents 30

Make sourcing decision 10

Send request to MSI team 10

Critical Path Tasks

ASB Capability Analysis 18

Load queue 5 30

Load data in ASB databases 155 152

Forging design 10 80

Verify inputs vs. outputs 120

Procure tooling 52

ICAD verification 90

ICAD error correction 23

Code as orderable 6 5
Takt time
0 50 100 150 200 250 300 350
Durations (Minutes)

New Duration Time Savings

©2001 The Timken Company 6

Instancing Process Kaizen Event
Results:
Improvements Old New Savings %

Base 556 279 277 49.8%

Base with Forge Design 646 374 272 42.1%

Base with Edits 561 279 282 50.2%

Base with Cones 608 279 329 54.1%

Base with Errors 601 324 277 46.1%

Weighted Avg Critical Path 615 311 304 49.5%

©2001 The Timken Company 7