Container Refurbishment Cycle Time Reduction (CTR) Project

Abstract

In mid-1999, a Cycle Time Reduction (CTR) project was initiated by senior management to improve the overall efficiency of the Container Refurbishment process. A cross-functional team was formed by the Industrial Engineering Services group within Product Certification Organization to evaluate the current process and to propose necessary changes for improvement. The CTR team efforts have resulted in increased productivity equaling approximately $450K per year. The effort also significantly reduced the wait time required necessary to start assembly work on the shop floor. Increasing daily production time and identifying delays were key team goals. Following is a brief summary of accomplishments: (A) Productivity Improvements: (1) Reduced Radcon survey time for empty containers: (i) 50% at 9720-3 (ii) 67% at 9204-2 and (iii) 100% at 9212; (2) Eliminated container inspections at 9720-3; (3) Reduced charged time (includes hands-on labor and support functions) per empty container by 25%; (4) Reduced cycle time to refurbish a container by 25%. (Dramatic wait time reduction -Assembly); (5) Reduced the time for 9212 to receive empty, refurbished containers by 67-80%; (6) Reduced the time for 9204-2E to receive empty, refurbished containers from 1 day to immediate; (7) Implemented software to track time charged per container for continuous improvement; (8) Initiated continuous improvement efforts between Workstream experts and Refurbishment personnel, reworded complex Workstream prompts to allow worker data corrections, and reduces time of support groups, Workstream personnel, and Refurbishment personnel; (9) Consolidated refurbished, container warehousing areas, eliminated long travel times to areas outside the protected area portals to an area in the vicinity of the refurbishment area and a process area, benefits are improved container flow and better housekeeping; and (10) improved overall communication of team by flowcharting entire process. B. Annual Cost Savings: $453K Annual Savings at a one time cost of $13K.