Training on a new process can be tricky but the door fit installation on Line 9 has more potential for damage than most….
This week, we speak to Line 9 Group Leader, Kevin Geggie, about the Kaizen he raised for the door check arm on our vehicles, which has helped to minimise damage, improve quality and make thousands of pounds worth of savings for Halewood.
“When fitting a new door, the associate is required to bring it in on a manipulator and slot it into position, without the door check arm making contact with the pillar on the vehicle.”
“If it does, this can cause chips or scratches to the paintwork on the A and B pillars of the car which then need to be retouched which is expensive.”
An experienced operator would be able to do this quite easily but it a skill that needs to be learnt and Kevin explained how new starters were finding it tricky as they need to be able to balance and hold the car at the same time to fix the door in.
Kevin said: “I wouldn’t like to think how much this was costing the business but to put it in perspective, we have a new operator joining the line every few months and during the first two-week training period, we normally report between 50- 100 damaged cars per person.
Keen to put an end to "armful" damage, Kevin worked with Joe Benson in ME and Kev Mellia in BIW Additive Manufacturing, to create a 3D prototype arm check cover. The cover helps to protects the pillar if it makes contact with the door check arm during docking- putting an end to preventable and costly chips to the car’s paintwork.
Kevin said: “Raising a kaizen is empowering because it shows how any idea- no matter how simple you think it is can make a big improvement to a manufacturing process. The arm check cover was a quick fix to a problem that has been causing us issues for many years now.
“The fact we have 3D printers on site is a game-changer as we were able to work with the teams in ME and BIW Additive Manufacturing to turn this round in a short space of time and are now looking at what other ideas we can action to make processes on our line run smoother.
Making small continual improvements through raising a Kaizen is a key way that employees can play their part in Refocus - our new day job in Manufacturing which is helping to transform the way we operate at Halewood to improve quality, sustainability, and the profitability of our vehicles.
Have you raised a Kaizen? Please share your experience with us by emailing: firstname.lastname@example.org