1. ERJ DIVE
Company Private
ACCESSORIES SHOP

2. DEFINE
2
,Bill Borah

3. DEFINE CONT’D
3
0
5
10
15
20
25
Apr May
LaborHrs
Months
ERJ Average Labor Hrs
(Current)

4. EVENT PRE-WORK ACTIVITIES
Part Family A
Takt Time:
129
Part
Number Description
Monthly
Demand Pre Test Disassy Cleaning Inspect
Shimmin
g Assy Test F. Prep
Total Work
Content
ERJ 75.0 45.0 60 60 150 250 160 40 30 720
Slat "CRJ" 30.0 45.0 60 60 150 240 160 40 30 710
Variation
%
0 0 0 0 4 0 0 0 1.39
Avg C/T 45.00 60.00 60.00 150.00 245.00 160.00 40.00 30.00 119.17
INVESTIGATE

5. INVESTIGATE CONT’D
5
MaterialsROAActuationQuality
Receive
Unit
Shop
Incoming
Pre-
Checks
Dissy. Insp
Pull parts
Assy.
Functional
Test
Final
Inspection
Final
Prep
Ship Unit
Incoming
PO
Review
Physical movement (Unit/paperwork)
Electronic communication
Internal process
45 Min. 2 Hrs 2 Hrs 10 Hrs 1 Hr
0.5 Hr

6. INVESTIGATE CONT’D
6

7. Count of SO Average Sum of Hrs
12 Hrs Target
Cum Avg 23.2
VERIFY CONT’D

8. Count of SO Average Sum of Hrs
12 Hrs Target
Cum Avg 23.2
VERIFY CONT’D

9. Progression Timeline
Contact ASE for
recommendations of SB
& CMM revision. Assign
Action items and commit
dates. Enhance shimming
process through SB
change
Create Special Tooling for
shim stack up.
Complete time
observation study of
current state & cycle time
reduction plan.
Conduct standard work
Kaizen event.
Order cleaning tanks.
Obtain spring tester PO
approval.
Obtain shimming
software verification if
standard shimming
process is not adopted.
5/23/11 5/28/11 5/31/11 6/5/11 6/10/11 6/15/11 6/20/11 6/30/11
Implement process gates
on all benches to monitor
times.
11Hrs
by
Aug 1
Benefits = 6Hr reduction
3Hr reduction
0.5Hr reduction
10 Min reduction
2 Hr reduction
20 Min reduction
See standard work
Kaizen
VERIFY CONT’D

10. ENSURE
No. Activity Owner Due Date
1 Enhance shimming process SB & CMM rec. Bowman/ Borah/ Dobbs 5/31/2011
2 Time observation study (current & future) Bowman/ Morales 5/31/2011
3 Incorporation of Process Gates Bowman/ Morales 6/1/2011
4 Standard Work Kaizen Event Bowman/ Morales 6/5/2011
5 SB ENG action items closed Borah/Porsche 6/12/2011
6 Spring Tester Quote and PO approval Bowman/ Mclaughlin 6/15/2011
7 Shimming software if standard shim process NV Anwar/ Bowman/Lyn. 6/30/2011
8 Order cleaning tanks Bowman/ Benn 7/1/2011
9 SB action item approval for standard shimming Borah/ Porsche 8/15/2011
10 Solvent PD680 added to CMM as alternative Borah/ Porsche 8/15/2011
% Complete
Team: ERJ Kaizen team Date: 08/05/11

11. ENSURE CONT’D
11
17.4
13.53
11.66
0
5
10
15
20
May-11 Jun-11 Jul-11
AverageLaborHours
Months
ERJ Current Labor Hour Trend (Monthly)
Monthly Average Labor Hrs
Goal 12 Hours
28 Units
June
26 Units
May
34 Units
July

12. TOTAL TIME CURRENT STATE 12HRS
MaterialsROAActuationQuality
Receive
Unit
Shop
Incoming
Pre-
Checks
Dissy. Insp
Pull parts
Assy.
Functional
Test
Final
Inspection
Final
Prep
Ship Unit
Incoming
PO
Review
Physical movement (Unit/paperwork)
Electronic communication
Internal process
45 Min. 1 Hrs 2 Hrs 7 Hrs 1 Hr
0.5 Hr
Reduced Times
ENSURE CONT’D