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Gore Sterilization & Packaging Process

Team Gore:

Shruti Babukumar, Berenice Castro, Erin Glavin, Phil Young

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Agenda

  • Strategically Recognize & Define
  • Measure
  • Analyze
  • Improve/Control
  • Standardize & Integrate
  • Summary
  • Questions

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Strategically Recognize & Define

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Context:

The process is considered to be moved to the Phoenix, AZ location.

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Purpose: To determine the amount of resources needed to have the process in Phx, which will help Gore decide whether to bring the process to Phx or outsource.

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Viewpoint:

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Deliverables:

  • Floor Plan
  • # operators
  • # workbenches
  • Schedule operations

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Define/Measure

Current State High Level Process Map:

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Measure

Current State Layout

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Object

Size

Workstation

5 ft x 3 ft

Cart

4 ft x 2 ft

Raw Material Station

6 ft x 1 ft

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Measure Phase

  • Average total time through the system: 264.7 mins ~ 265 mins
  • Current # of stations in Flagstaff: 8
  • Yield: 99 %

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With 20% adjustment

Vascular Graft (VG)

Patch

Demand Volume Average

327

324

Demand Volume Max

371

382

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Analyze

  • Demand Max
    • VG 371
    • Patch 382
  • Sterilization Max Capacity
    • 2 & 3 Loads

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Analyze

Utilization Assumptions:

  • 4 Associates too high of utilization
  • Setup time not accounted for
  • Layout could lead to time differences (Phoenix vs Staff)
  • Percentage does not include breaks or lunch

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Floor Layout

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Improve

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*Assumption: End shift time in Flagstaff is 6:00pm

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Summary of Expected Improvements

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System

Current State

Future-State

# of Operators

6

5 (~$35,000/yr)

WIP Reduction

-

~$34,000

Total Transport Time

360 minutes

~120 minutes

Boxing Materials

-

-650 boxes/annually

Patch

Current State

Future-State

Cycle Time

20.5 hours

8.5 hours (-59%)

Throughput

16.6 units/hour

40.1 units/hour

Efficiency

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141% increase

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Control Considerations

Monitor labor and utilization of Phx process

    • Make necessary adjustments in scheduling/staffing

Track various metrics:

    • # of loads/day
    • Demand data
    • Trends

Conduct further time studies:

    • Run updated time studies on new process
      • Compare with process performance
    • Identify learning curve
      • For training/staffing projections

Interview Associates re challenges in process

*Standardize: Develop SOP to streamline process

*Integrate: Ship other products directly in baskets

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Conclusion

  • Strategically Recognize & Define
  • Measure
  • Analyze
  • Improve/Control
  • Standardize and Integrate
  • Summary
  • Questions

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Questions

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Estimated Monetization of Transport Savings

Labor:

Gross driver compensation ~$60k

260 working days (2017) – 10 vacation days = 250 working days

Labor cost = $240/day

Operating costs:

Annual Insurance estimation: $3000/yr = $12/day

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Maintenance $.12/mile = $29/day = $7,260/yr

Total Operating cost =$340/day = $85,000 annually * (2lf/15lf) = $11,300 annual travel cost reduction

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Backup Throughput calc & Removed notes

This removal represents a reduction in transport time of 67%

Another improvement is the removal of the tertiary boxes (250 working days X 2.5 boxes/day ~650 boxes and decrease loading time

WIP reduction - decrease cycle time - Little’s law quantify this

Convert to dollars - estimate capital dollar in

Consider use the map on first page and show then show that it is not moving

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References

https://www.esutures.com/product/1-expired/46-gore/231-cardio-patch/18298-gore-tex-cardiovascular-patch-cardiac-5cm-x-7.5cm-x-0.6mm-1705007506/

Glassdoor:

https://www.glassdoor.com/Hourly-Pay/W-L-Gore-Manufacturing-Operator-Phoenix-Hourly-Pay-EJI_IE3044.0,8_KO9,31_IL.32,39_IM678.htm

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