Test Method Workshop Introduction

Test Method Workshop – JMMK Washcoat
introduction
Pavle Jovanov / Igor Acevski
Test method workshop
Main activities:
• Preparation of WASHCOATs according already defined specification and standard production

process
• Production process is separated in three main areas: Slurry prep, Washcoat batching and Final
adjustment
• Main target KPI’s to achieve
• Use as a guide in everyday work the standard JM EHS frame: Communication, Involvement,
Standard and Risk assessment.
Insert footer here 2

Organization chart:
• 4 teams that covering 24/7 production
Each team have 20 operators , 3 deputies supervisor, material control and Supervisor
• 2 project coordinators and one project engineer
• Washcoat planner
• Assistant manager and Washcoat Manager

Organization chart: Gilbert Goscicki
Manufacturing
Manager
Ivanka Nedeljcin
Igor Acevski Maja Mitrevska Dean Jordanov Asistant Washcoat
Dime Ilijoski Jovche Cvetkov
Project Coordinator Project Coordinator Washcoat Manager Project Engineer Washcoat Planner
Manager
Bojan Gjorgjievski Pavle Jovanov Ivana B.Savikj Igor Nikolovski

Kire Paunovski Nenad Stupikj Irena Peshevska Darko Toshevski
Slagjan Jakimovski Chemical Coating Chemical Coating Chemical Coating Chemical Coating
Chemical Coating Material Controller Material Controller Material Controller
Material Controller Supervisor Supervisor Supervisor Supervisor
Supervisor
Marina Novchevska Nenad Petkovski Oliver Stefanovski Tome Trajkovski Dragana Stojkovska Vlatko Kostovski Viktor Angelkoski
MItko Trajkovski Ljupcho Ivanovski Jovanche Gajdov Vladimir Stoilovski Sasha Stojanovikj
Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical
Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical Deputy Chemical
Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor
Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor Coating Supervisor
Vasil Janevski A. Trajkovski Zoran Jankovski Pero Cvetanovski Marjan Gjorgievski Dejan Dimovski
Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Aneta Jovanovska Zoran Angeloski
Operator Operator Operator Operator Operator Operator Chemical Coating Chemical Coating
Operator Operator
JovIca Jankulovski Daniel Petrov Mladen Spasovski Igor Kavazov Martina Stefanovska Dejan Petkovski
Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Aneta Ivanovska Jovanche Hristov
Operator Operator
B. Trajkovski Angel Mihajlov Miroslav Gogovski Goran Vukashinoski A. Stojanovska Emilija Naumovska
Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Mile Dimeski Jane Bocevski
Operator Operator
Lidija Kostova Ivica Zlatevski Dejan Jankulovski Katerina Dimovska Hristijan Stojanovski Frosina Kostevska
Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating Chemical Coating
Vladimir Krstevski Darko Dogandjiski
Operator Operator Operator Operator Operator Operator
Chemical Coating Chemical Coating
Operator Operator
Dimche Petrov Biljana Angelovska Zoran Dimov Ivica Todorovski Igor Krstevski Irena Trajkovska
Operator Operator Operator Operator Biljana Manevska Vane Georgievski
Operator Operator
Marija Jovanovska Vladimir Siljanovski Igor Ilijevski Zlatko Velkovski Afrodita Simonova Biljana Vasilevska Operator Operator
Operator Operator Operator Operator Operator Operator Jovica Krstevski Darko Manevski
Valerija Slavkova K. Nedelkovska Gjorgji Trpevski Daniel Kuzmanovski Ivica Vasilevski Elena Ilievska Operator Operator
Operator Operator Operator Operator Operator Operator Boban Petrushevikj Ivana Mitrovska
Goran Jovanovski Vesna Ristovska Goran Peev Zlatko Kaskarevski Daniel Andonovski A. Blazhevski Operator Operator
Operator Operator Operator Operator Operator Operator Sanja Kocevska A. Gjoshevski
Elena Trajkovska Dejan Dimitrievski Eleonora Trajkovska Elisaveta Efinova
Tatijana Tasevska Bojan Antevski Operator Operator
Chemical Coating Chemical Coating Chemical Coating Chemical Coating
Operator Operator Operator Operator
Operator Operator Jasmina Kirakovska Pero Vasilev
Aleksandar Todev Gorjan Dimchevski Marina Trajkovska Nenad Naskovikj Chemical Coating Chemical Coating
B. Milivojevikj D. Dragomirovska
Chemical Coating Chemical Coating Operator Operator
Chemical Coating Chemical Coating Chemical Coating Chemical Coating
Operator Operator
Operator Operator Operator Operator
Team IV
Team I Team II Team III

Proud Key:
Washcoat Game Changer project

Proud Key:
Washcoat Game Changer project:
With increasing demand for JMMK, there was a need to review the way of working in the washcoat
department and identify further actions for sustainable growth using the existing equipment and
same number of staff.
Several workshops were organized using a Value Stream Map approach which helped to identify
areas for improvements:

Proud Key:
The Washcoat batching process is a complex combination of thousands of unique operations each month.
If not carefully arrange these operations can easily obstruct each other, creating traffic jams everywhere.
The WC Gamechanger project aims to:
 Reduce the traffic by working on right tanks

 Eliminate waiting time
 Smooth the process of peaks and valleys to keep a constant rate of unique operations at any given time
 Improve workstations with highest process time
 Ensure that the team understand what needs to be completed and by when

Proud Key:

Benefits
• Reduce finished WC safety stock from 4.6 days to 3.2 days YTD average
• Improved batching time allowed restrictions to be removed from planning
• Running multiple passes back to back
• Increased allowable 4000L PGM tanks usage from 31 to 42
• Increased allowable 4000L SCR tanks usage from 18 to 32
• Less PGM storing in WC which allowed Salts inventory to be reduced
• Significant capacity opened
• Significant drop in energy usage per tonne of WC
• More clear visibility into capacity improvement needs
• Improved employee morale

Proud Key:

Average batching time per year
70
59.6
60
50
Average batching time
40
30.5
30
23.2 18.4
20
10
0
13/14 14/15 15/16 16/17
Year

Proud Key:

160
Average Tank Turnaround per year

140 137
120 111.5
100
79.6 75.9
80
60
40
20
0
YTD 13/14 YTD 14/15 YTD 15/16 YTD 16/17

Proud Key:

Bathing time/Number of batches per month
Batching time Number of batches
35 600
30
500
25
400
20
300
15
200
10
100
5
0 0
15 15 15 15 15 -1
5
l-1
5 15 15 15 15 15 -1
6 16 16 16 16 -1
6
l-1
6 16 16 16 16 16 -1
7 17 17 17
an- eb- ar- pr-
ay- n u u g- ep- ct-
ov- ec-
an eb- ar- pr-
ay- n u u g- ep- ct-
ov- ec-
an eb- ar- pr-
J F M A M Ju J A S O N D J F M A M Ju J A S O N D J F M A

Key challenges:
One Pot
 With increasing demand for JMMK new key challenges for washcoat department is One pot process.
Because of the financial cost savings and the long time for delivery the Cu zeolite from suppliers in future
to satisfy the demand we will buy separately CU and zeolite and here in our factory we will make the
process of tying.
SCRF – wet milling

 According increasing demand for SCRF filter and because the long process of milling will be installed
additional equipment on 15m to satisfy the suppliers demand
- Installation on new 3 mill and 4 prep tank, 7 storage tank plus flexicon unit

Test Method Workshop Introduction

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Test Method Workshop Introduction

Uploaded by

Copyright:

Available Formats

Test Method Workshop – JMMK Washcoat

• Preparation of WASHCOATs according already defined specification and standard production

• Main target KPI’s to achieve

Insert footer here 2

• 4 teams that covering 24/7 production

• 2 project coordinators and one project engineer

• Assistant manager and Washcoat Manager

Insert footer here 3

Bojan Gjorgjievski Pavle Jovanov Ivana B.Savikj Igor Nikolovski

Insert footer here 4

Washcoat Game Changer project

Insert footer here 5

Washcoat Game Changer project:

Insert footer here 6

Washcoat Game Changer project:

The WC Gamechanger project aims to:

 Reduce the traffic by working on right tanks

Insert footer here 7

Washcoat Game Changer project:

• Improved batching time allowed restrictions to be removed from planning

• Running multiple passes back to back

• Increased allowable 4000L PGM tanks usage from 31 to 42

• Increased allowable 4000L SCR tanks usage from 18 to 32

• Less PGM storing in WC which allowed Salts inventory to be reduced

• Significant capacity opened

• Significant drop in energy usage per tonne of WC

• More clear visibility into capacity improvement needs

• Improved employee morale

Insert footer here 8

Washcoat Game Changer project

Insert footer here 9

Washcoat Game Changer project

Average Tank Turnaround per year

Insert footer here 10

Washcoat Game Changer project

Insert footer here 11

SCRF – wet milling

Insert footer here 12

You might also like