Rourke Adams
Engineering Coordinator,
Honda – Marysville Ohio
Driving Process
Improvements using
Efficiency Monitoring
Marysville Ohio Weld
Department
Accord
Acura TLX
Acura ILX
A Mobility Company
15
North American
production
facilities
Honda Marysville Auto Plant Overview
MAP Line #1 & Line #2
Plant Size: 3.5 million sq. ft.
Production – 1980 units/Day
Quality
Engineering
Paint
Accord
Plastics
Bumper Paint
Weld
Stamping
Acura TLX
Assembly
Export
Acura ILX
Honda
Engineeringa
Vehicle
Quality
line 2
line 1
Material
Service
Honda Philosophy
The genba is always
changing and there is always
room for improvement.
Genba (現場) is a
Japanese term
meaning
"the real place."
Using Incident Properties allows us to
include detailed information (i.e. Robot
Number help us determine which robots
have consistently had trouble)
Efficiency Monitoring – Marysville Auto Plant Weld
Cause Code Structure similar to other Honda Plants
Efficiency Monitoring – Marysville Auto Plant Weld
Weld Incident Properties
Incident Properties allow users to
assign:
Area Responsible, Follow Up,
Model, and Process
This Detail is to help define
specific processes or robots.
Efficiency Monitoring – Marysville Auto Plant Weld
Weekly feedback process?
1. Top 3 RCA Problems feedback
weekly to Area’s
2. Each Area implements improvement
activities for the Top 3 Problems
Efficiency Monitoring Reporting
Efficiency Monitoring Reporting
Departmental Summary Report for Production Results and Key Downtime Occurrences
MAP Weld Visual Management
MAP Weld Visual Management
What is the benefit of VM.
1. MTTR Reduction – Real time
notification of equipment stop.
2. Operation Status
• Starved, Blocked, etc.
• Production Plan/Actual/Gap
MAP WE has 48 Visual Display’s
Efficiency Monitoring – Marysville Auto Plant Weld
MAP WELD Operator Load Screens
Currently 18 Operator Load Screens Installed at the processes Additional
Load Screens Planned for Dzones
Line 1 Azone:
Rear Inner
Rear Floor
Front Floor
Front Comp
Line 1 Bzone
Left Side Panel Outer
Right Side Panel Outer
Stiffener Comp
Roof
Line 1 Dzone
Trunk
Line 2 Azone:
Rear Inner
Rear Floor
Front Floor
Front Comp
Line 2 Bzone
Left Side Panel Outer
Right Side Panel Outer
Stiffener Comp
Roof
Line 2 Dzone
Trunk
MAP WELD Operator Load Screens
MAP WELD Operator Load Screens
MAP WELD Operator Load Reporting
20
L1 Frt Comp W/House Preset Process Starved by
Qtr in Minutes
20
15
15
10
10
5
2.7
2.0
0.0
0.0
1.4
L1 Frt Comp LWR DA/BD Preset Process Starved by
Qtr in Minutes
4.6
5
0.0
1.0 0.0
0
2.5
0.3 0.0
0.0
1st Qtr
2nd Qtr
1st Qtr
2nd Qtr
3rd Qtr
4th Qtr
T2F/G
20
0.0
0.1 0.0
3rd Qtr
4th Qtr
0
T2F/G
L1 Rr Flr Lg Parts Process Starved by Qtr in
Minutes
L1 Rr Flr Sml Parts Process Starved by Qtr in
Minutes
20
15
15
10
10
5
5
10.2
5.1
0.0 0.0
0.2 0.0
0.1 0.0
0.1 0.0
0
0.0
0.9 0.0
1st Qtr
2nd Qtr
1.5
0.0
0.0
3rd Qtr
4th Qtr
0
1st Qtr
2nd Qtr
3rd Qtr
T2F/G
4th Qtr
T2F/G
Custom Reporting
MAP WE Operator Load Screens
How do Operator Load Visual Management
improve efficiency?
1. Operators self monitor and improve their
own load time
2. Reports identify trends and allow team
leader to implement improvement activities
Operator Load Visual Management
L1 Frt Comp W/House Preset Process
Starved by Qtr in Minutes
20
15
15
10
5
L1 Frt Comp LWR DA/BD Preset Process
Starved by Qtr in Minutes
10
4.6
5
2.7
2.0
0.0
0.0
1st Qtr
2nd Qtr
1.4
0.0
1.0
0.0
0
2.5
0.3 0.0
0.0
1st Qtr
2nd Qtr
20
0.0
0.1 0.0
3rd Qtr
4th Qtr
0
3rd Qtr
4th Qtr
T2F/G
T2F/G
L1 Rr Flr Lg Parts Process Starved by
Qtr in Minutes
20
15
15
10
10
5
5
L1 Rr Flr Sml Parts Process Starved by
Qtr in Minutes
10.2
5.1
0.0 0.0
0.2 0.0
1st Qtr
2nd Qtr
0.1 0.0
0.1 0.0
3rd Qtr
4th Qtr
0
0.0
0.9
0.0
1.5
0.0
0.0
3rd Qtr
4th Qtr
0
T2F/G
1st Qtr
2nd Qtr
T2F/G
Min/Day
20
80
70
60
50
40
30
20
10
0
70
9
13% short
stops
reduction
61
$934K
Before
13% Reduction
After
yearly
cost
savings
Overall MAP WE ActivPlant Benefit
MAP WE Short Stop Trend
120
117
24%
110
102
Min/Day
100
89
90
short stops
reduction
$2.7Million
80
yearly cost
savings
70
60
88 Ki
89 Ki
90 Ki
How achieved?
1. 13% Operator Load Screens
and follow-up
improvements
2. Weekly Top 3 Problems by
area issued for
improvements
3. Using ActivPlant data to
identify trends for
improvement activities.
ActivPlant only supplies the
data – Associates acting on
the data is the KEY
Benefits Examples
From Other Honda Locations
MAP Stamping:
AEP Engine Line 2:
+3.1% Run Rate Improvement (Dec) from Process Stopper reports identifying
bottlenecks.
$164,400 Annual Overtime Avoidance & ½ MP Manual Reporting Avoidance
TL Report:
Stopper 24: +5.4% Run Rate
AE2 – TPA Example – Conrod data input – B4 Data Input (Stopper 024)
Summary Report:
Problem Identification
Stopper 024
92.9% Run Rate
178 cycles over line speed
30 min loss
After talking with assoc we realized the camera
read rate was poor.
PC Report:
After countermeasure
Stopper 024
98.3% Run Rate
32 cycles over line speed
8 min loss
After installing a new camera light the read rate
improved and the associate met the target run
rate of 97%
Stopper 32: +6.3% Run Rate
AE2 – TPA Example – Oil Jet Install – (Stopper 032)
MAP Stamping Efficiency Improvment
Problem Identification
80.0
Stopper 032
92.9% Run Rate
178 cycles over line speed
30 min loss
Machine light curtains were going abnormal
almost every cycle
After countermeasure
Stopper 032
99.2% Run Rate
48 cycles over line speed
3.6 min loss
Installed new safety relays to fix light curtain
abnormals
16.1% Avg
Effic Gain
75.0
70.0
Efficiency %
Process Stopper Daily
Summary & Trend Reports:
+16.1% Efficiency Game from
Key Delivery Reports and real-time RCA Downtime Tracking
65.0
60.0
55.0
50.0
45.0
40.0
89 Ki Q3 Avg
B-Line
C-Line
89 Ki Q4 Avg
D-Line
90 Ki Q1 Avg
Blanker #1
Blanker #2
Questions?