Metalphoto® Kaizen

A kaizen event is similar to a cross-functional project team where a group of employees tackle an “opportunity” (a.k.a a big fricken problem) to better the company by means of identifying and reducing waste. The Metalphoto® department has grown significantly over the years at WNP. The CTP (Computer-To-Plate) machine was the latest addition along with two large tanks for sealing and rinsing. The room was in serious need for redesign with crammed quarters along with ergonomic and safety issues. A cross-functional team was selected and consisted of: Ricky Bailey, Michelle Bartrum, Stacy Coan, David Daly, Jeff Dwyer, Jess Mitchell, and Terilee Serrambana.

The event started with the drafting of the team charter. This is a road map for identifying the problem, scope, team, schedule, and measurable goals to accomplish during the kaizen event. Details are listed as follows:

Problem statement: The department had to be redesigned concerning efficient flow, new equipment additions, environmental controls, and safety/ergonomics.

Scope: This is the boundaries of the kaizen. Metalphoto with supporting departments of Prepress and Mechanical.

Measurable Goals: (all goals were met except for #5)
1) Educate members on 6s, 7 Wastes, and Swim Lanes.
2) Define product mix and swim lanes.
3) Each member to draft a new layout of Metalphoto.
9 total + 3 future state cell designs
4) Document current and future state flow.
5) Develop visual controls and standard work.
TBD after construction
6) Environmental, Health, and Safety improvements.
9 safety/ergonomic improvements identified
7) 6S Audit Baseline.
Kaizen team gave 1.60
8) Identify 7 wastes in Metalphoto.

Cycle time was analyzed on both the light table and CTP with the following results:
CTP – batches of 10 sheets every 25 minutes created a continuous flow, which equates to 192 sheets every 8 hours.
Light Table – batches of 24 sheets every 25 minutes creates a continuous flow, which equates to 456 sheets every 8 hours.
In conclusion, the light table processes every 50 seconds whereas the CTP processes every 2 minutes. The CTP is newer technology and will eventually phase out film and the light table.

NEXT STEP
Builders have been contacted and a temporary Metalphoto department consisting of just the light table, processor, tanks, dryer, shear, and sink will be created in a large portion of the Pad Print room. The Pad Print machine will not be moved. Prepress will work ahead and construction is expected to take 2 weeks.