“ Chasin hasing g Wa Waste” Utilizing til izing 6sig 6sigma ma and and Caterpilla terpill ar Producti rod uction on Systems (CP (CPS) to Achieve Ach ieve Envi Enviro ronment nmenta al Goals
Facility Overview •
Facility Opened in March 1998
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30 Acre Site
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183,000 Square Feet
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Current Active Emplo yees – 15 Caterpill ar Management – 155 Caterpillar Hour ly – 15 Contract Workers (Maint enance and Chemical Management)
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Second Largest Manufacturing Employer in Oxford
Product Line The Caterpillar High Performance Extrusions (HPE) Facility manufactures high-pressure hydraulic hose couplings for use with Caterpillar XT hose in all available sizes from 3/8" to 2" in diameter. These couplings are assembled from components that have been machined from near net shape extrusions, or cold-formed steel basics. There are several steps in the process of manufacturing these couplings. These include Annealing, Coating, Extrusion, Machining, and Assembly.
Tornado February 5, 2008
Opportunity Caterpillar looked upon the rebuilding process as an opportunity to make improvements to the facility. Some of those improvements were specifically aimed at improving environmental performance. • New energy efficient lighting • New energy efficient HVAC units • New insulated white roof system • Redesigned wastewater treatment system • Redesigned chemical storage area
2009 Environmental Goals and Accomplishments • Goal: 90% recycled material (Year end results 97%) • Goal: <12,500 mt CO2 equivalents (Year end results 7,750) • Goal: <12.5m gals municipal water (Year end results 6.8m gals)
2010 Environmental Goals • Goal:100% recycled material • Goal: <8,500 mt CO2 equivalents • Goal: <7.5m gals municipal water used
6Sigma Caterpillar launched 6Sigma globally in 2001. 6Sigma methodology is used to focus on “real problems”. It allows quick results and helps sustain improvements.
DMAIC Process Define – How is business impacted? Measure – What is the extent of the problem? Analyze – What is the root cause? Improve – What is the solution? Control – Implementation plan
6Sigma (Reduction of Spent Cleaner- Example)
Define – Spent cleaner volumes were too high Measure – Drag out and carryover was contaminating cleaner tanks
A nalyze – Barrels are not allowed to rotate and drip before moving to next station
Improve – Add dwell time and rotation to programs to allow excess material to drain before moving to next station
Control – Train employees and Implement changes to all Standard work documents
Caterpillar Production Systems (CPS) •
In 2006 Caterpillar implemented CPS to provide commonality across the various processes
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CPS consists of three sub systems and fifteen guiding principles
The Operating system is focused on waste elimination using 6Sigma and lean tools. Guiding principles are; Chase Waste, Pull, Make Value Flow, Drive Standard Work,Even the Lo ad, and Valid ate our processes The Cultural syst em is focused on making change possible and improving the way we work. Guiding principles are; Put Safety Firs t, Take the Customers View, Go,See,Act, Sto p to Fix, Develop People. The Management s ystem is focused on creating measurements and the management structure to support continuous improvement. Guiding principles are; Activel y Listen, Make it Visual, Align the Targ ets, Ac t Decisively
8 Wastes
Caterpillar Production Systems (CPS) • • • • • •
Make it Vis ual/Align the Targets – Communicate goals and post results so that employees can see progress. Make Value Flow - Standardized scheduling and flow at the phosphate coating operation reduced waste from over processing and re-work. Go,See,Act – Empower employees to make suggestions and report activities that don’t comply with procedures (Continuous Improvement cards). Drive Standard Work - Standard Work created to shutdown boilers and other high energy use equipment during extended shutdown periods. Develop People – Establish training program for all employees on waste minimization and recycling program. Valid ate our Processes – Investigation of water usage created 6Sigma project to reduce water consumption through flow restriction and recycling of water.
Questions? Thank You!
