THE FIRST TRY AT THE LAYOUT
With the sequence of operation clear, knowing that they needed an isle around the outside of the line, and that the line needed to be operable with only 1 person, as well as knowing the basics of Just in Time, Quality in Station, and 1 Piece Flow, the layout of the line started to take shape.
HARRY POTTER. PROBLEM CHILD
The epoxy potting machine, affectionately known as "Harry Potter," gave the team a lot of trouble. Why did it need to be vented? The team checked the Material Data Sheet and found that it was the catalyst that needed venting. But the catalyst was in a sealed vessel. Did it still need to be vented? And come to think of it, how does one know when to refill? With no gauge on the tanks... no one does! And the nozzle reaches very far away from the machine... but the work is done close to it. Harry was full of riddles.
OLD WAYS TAKE UP SPACE
As the equipment was set up, these test baths at the left needed panels and wires that ended up in the isle. Time to kaizen!
THIS'LL DO FOR NOW
The team found a discarded rack to put the panels on. It was steel so it will rust eventually over the steaming baths, it didn't allow much visibility... there are many problems with it but it got the panels out of the isle for now. "Sophistication delays, so choose speed."