This document discusses a project to improve the production process for LTTT rollers at a Caterpillar plant. The project aims to implement a lean flow to reduce total cycle time and increase capacity by reengineering the assembly line layout. Initial analysis found bottlenecks in specific production operations. The project identified opportunities like adding an automatic screwing station and palletizer. Early results demonstrated a 25% improvement in internal capacity and lead time. Ongoing work focuses on further optimizing performance by monitoring overall equipment effectiveness. Lessons learned include involving operators in decision making and breaking down barriers between departments.

1. Caterpillar Mec-Track
Officina delle Operation Novembre 2012
Value Stream Transformation
Flusso Rulli LTTT
Team Leader:
Benedetti Giancarlo
Logistic Manager
CPIM Certified
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Steel Products
MAKING SUSTAINABLE PROGRESS POSSIBLE
Remanufacturing &
Components Division CATERPILLAR CONFIDENTIAL: GREEN

2. Sicurezza
Un Impegno Quotidiano
• Qual’è l’uscita di emergenza più vicina?
• Dov’è l’estintore ?
• Dov’è la cassetta di pronto soccorso ?
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3. Chi è la Mec Track
Bazzano
Total Area: 394,397 Square Ft
Covered Area: 186,205 Square Ft
Employees: 246
Castelvetro
Total Area: 150,055 Square Ft
Covered: 78,038 Square Ft.
Employees: 36
San Eusebio
Total Area: 43,055 Square Ft.
Covered: 16,145 Square Ft.
Employees: 38 Caterpillar: Confidential Yellow
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Remanufacturing &
Components Division CATERPILLAR CONFIDENTIAL: GREEN

4. Caterpillar Undercarriage –
Cosa produciamo
Carrier Rollers
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Idlers
Remanufacturing &
Components Division CATERPILLAR CONFIDENTIAL: GREEN

5. TTT Rollers (D3 to D11) HEX Rollers (315 to 390) MTTT Carrier Roller (D6 to D7)
TTT Shaft (D6 to D11) TTT Idlers (D6) LHEX Idlers (345 to 390)
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Remanufacturing &
Components Division CATERPILLAR CONFIDENTIAL: GREEN

6. Progetto VST
Progetto VST per
per Large
Large Tractors
Excavators
M9 Q4 2011
Q1 2012
M11 Q3/Q4 2011
Progetto Paint:
approvare RFI per
verniciatura VS02
Q1 2012
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Remanufacturing &
Components Division CATERPILLAR CONFIDENTIAL: GREEN

7. This project will support the implementation of the The actual Cat Mec Track lay out doesn't support a lean
Future state creating a flow for the production of the flow.This creates excess inventory and transportation,
LTTT rollers in order to reduce the reduce the Total that are the main waste on the process.Creating a more
Cycle Time and Increase overall capacity lean flow in order to reduce the TCT.
This is fully aligned with the CSF Velocity
Y1 Reduce LTTT Rollers TCT ( Turning +Assembly)
Y2 Increase total internal capacity to align to machine In Scope: Production Process flow for LTTT Rollers,
capacity
components replenishment process for LTTT.
Reengeenering of the assembly line
X: Create a detailed, process by process, VSM for LTTT
rollers
To be used in subsequent project for Redesign Mec
Out of Scope: Heat treatment, component supply, paint
Track lay out for LTTT and shipping
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8. Focus Progetto
A7 A5
M11 M9
Verniciatura Verniciatura
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9. Analisi attività per linea
OP1 Collo di bottiglia
OP1 Collo di bottiglia D10
OP2 collo di bottiglia D11
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10. Ricerca delle opportunità sul Processo
A5-M9 (VS5)
Attesa +
Attesa OP
trasporto
Tornio
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11. Ricerca delle opportunità sul Processo
A7-M11 (VS7)
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12. Individuato modifiche tecnologiche
VS5 ; nuova stazione avvitatura
VS7: Pallettizzatore
automatico Caterpillar: Confidential Yellow
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13. Miglioramento potenziale
Possiamo ridurre il tempo STD ,
aumentando l’output delle linee del 25%
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14. Valutato anche l’aspetto sicurezza ed
ergonomia
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Measure
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15. Individuato criticità per gestire
l’implementazione
 Rompere il concetto di appartenenza al reparto
 Differenza di trattamento tra i reparti
 Diversi responsabili
 Individualismo rispetto a lavoro di squadra
 Mi state chiedendo di fare di piu’
 Operatori non coinvolti nelle scelte
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16. STRATEGIA DI IMPLEMENTAZIONE
Lancio di due RIW
Scopo:
Definire e testare gli SW
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17. Rianalizzato attività per linea
OP1 Collo di bottiglia
OP1 Collo di bottiglia D10
OP2 collo di bottiglia D11
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18. Definito il lay out bordo linea
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19. Creato SWS per i 3 operatori
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20. Generate piu’ di 50 idee di miglioramento
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21. Comunicazione agli RSU
Costanti aggiornamenti in particolare rivolti a verificare
la parte ergonomica
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22. Risultati di produttività interna
25%
di miglioramento
dimostrato su capacità
e
lead time
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23. Continuiamo a lavorare per raggiungere il
target monitorando l’OEE
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24. Cosa abbiamo imparato
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25. Abbiamo anche imparato che..
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26. Caterpillar: Confidential Yellow
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