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1. LTL Shipping date column N column J Step 106 Save the file as LTL Report Pareto Analysis in ast milatue Of itern_dese_2 4 cumulative Hoe AJ om UU COL CAR 2 100 00 2 pe COL STARTER 242 86 EECH 70 00 EH 50 008 0 0 30 00 _ Po nome ooo OT Ea ey aE ESS eg Le 10 00 000 N b a w p TLS 4AL4YLS 02 Wall waaa Kl E KH pT KH PER PT TT Bee Pen SS __ LC Aug 11 2010 NOTE 25 not 35 operation Please check the 25not35 report for more details Part 4 Pareto Chart Pareto Chart is prepared for 1 Operation 25 not 35 2 Operation Status 15 not 5 25 not 15 35 not 25 3 Lazy Reports 2010 Millennium Infologic All rights reserved Millennium University Note A total of 8 charts need to be prepared For Operation Status Step 1 Open a spreadsheet and add 3 tabs at the bottom namely 15 not 5 25 not 15 and 35 not 25 Step 2 To draw Pareto chart select the option to draw a Bar Graph Step 3 Open the spreadsheet 15 not 5 and go to column H Item_desc_2 Step 4 Filter the values and click on each item listed one by one Step 5 Find the number of items in each category and note it down Step 6 Do the same for all the filtered items Step 7 Copy the Top 3 items based on the count and paste it in the spreadsheet meant for Pareto Chart Step 8 Those items copied will be the values in X Axis of pareto chart
2. a D 3 a CO O Oo n 3 3 D D a 5 oa 1 O gt g D bal Ko Q D 3 TD oO n E TD Ei lt m gt n S bh gt 0 Q D TD oO LA Ri gt 0 Q 3 o Q a N D n oe lt OD D 2 a Q o ke m gt a S bk gt 2 gt o 3 3 D o 2 5 5 o 5 OH 1 O D gt D Q Ko Q D pe fo n E TD Ei lt m gt n S bh Ee gt 0 Q D TD o LA Ri gt oO Q 3 o Q a N D a te lt o D 2 a Q o be m gt a 0 Ee gt 2 gt a O 2 D A D 3 3 o Q ER 3 D 5 A fo n 9 mi gt D 3 D Q Si S Q gt D gt Cc ES D 2 n a E b E A o D Q 2 a n o Q D o n Q w x _ TD Di REE no a st o Hi Ss 21210 O oslo n EE oa gt oO es 2 2 Q Q n co h S IER elle les i Olas D o JBE 2 3 Q bo Di lt 2 Q eh SA 3 oO n E n oO oO j Q O E Di CH SI E 5 O Di Q OD Si O Di Q OD be Si 3 D D Si OD Oo 1 O a gt OD Q Lu 2 jos 2 oO 2 jos 3 o 3 lt Q D lt 5 2 Q D c au n C n oO g jos Di Q E gt O E D Q D 3 D D gt D UU U US n n e a D 5 a
3. 5 2nd shift Ensure Leads have Extruder covered by pit crew for last portion of the shift 6 2nd shift Ensure Leads have Extruder covered by pit crew for last portion of the shift 5 Ensure lead has completed end of shift documents 6 Ensure lead has completed end of shift documents 5 Ensure press partners have cleaned organized and the shift change 1st to 2nd transition is smooth 6 Ensure press partners have cleaned organized and the shift change 1st to 2nd transition is smooth 5 Ensure the area was left clean and organized for end of day 6 Ensure the area was left clean and organized for end of day 5 Ensure press partners have gone on time 6 Ensure press partners have gone on time 5 2nd shift Ensure pit crew cleaned out extruder 6 2nd shift Ensure pit crew cleaned out extruder 5 Ensure all molds are emptied 6 Ensure all molds are emptied 5 Ensure partners finish trimming remaining mats and finish rolling and stacking on pallets 6 Ensure partners finish trimming remaining mats and finish rolling and stacking on pallets 5 Ensure trim area is cleaned and organized 6 Ensure trim area is cleaned and organized 5 Ensure Trimmers and Rollers have gone by 2 30 am 6 Ensure Trimmers and Rollers have gone by 2 30 am Q gt D Q E 3 Gi gt D 3 as Di 3 a 2 oO d 3 Gi St gt D Q Di lt 5 0 2010 Millennium Infologic All
4. By Shop order number on screen Activity by shop order report Step 91 Paste the shop order number in the corresponding place in macola Step 91 Click OK button Step 92 Select option screen and press OK on screen Activity history report Note Now you can see the current status of each operation Step 93 Note down the date and put the same in corresponding column in spreadsheet DRAW PARETO CHARTS Refer Part 4 Part 3 LTL and Open Orders Step 94 Log on to Citrix and open the link FM to MM access file on screen Fanmats open order information Step 95 Hit the Refresh button and wait until done pop up comes Step 96 Click on Open order with Tracking button on screen Open order report 2010 Millennium Infologic All rights reserved Millennium University Step 97 Export the values to a spreadsheet and make the alignment proper Step 98 Add 2 columns Time passed from shipping date and Checking date Step 99 Go to Pkg Shipping dates column I and filter the values Step 100 Now copy all the values and save it in a new spreadsheet Step 101 Apply the formula in column M The formula is Checking date Pkg Shipping date column N column J Step 102 Save the file as Open Order Report Step 103 Similarly Go to LTL Shipping date column J and filter the values Step 104 Now copy all the values and save it in a new spreadsheet Step 105 Apply the formula in column M The formula is Checking date
5. Q aD D Qa 5 O1 O ST oO O r 3 Di D a 3 2 S z Y Ka Oo n oO 3 Di D n D oO a Q Es 3 2 oO Qa det O Les Qa si Di lt O 9 D oO Fe oO x Q S oO Di n OD n S oO 10 30 AM 3 SE N D o o D gt Q o Leg n gt bd a ke Si TD a lt gt D D Qa D CO P6 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed 5 Check coverage in all positions due to break time on the lines 6 Check coverage in all positions due to break time on the lines P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any 9 30 PM adjustment by QA partners P5 Check trimming operation Make sure the trimming is being performed to the work instructions P6 Check trimming operation Make sure the trimming is being performed to the work instructions P5 amp P6 Check perforating and mat rolling operation Ensure it is being performed according to work instructions 5 amp P6 Check logo matching and rolling to ensure it is being done on time P5 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out P6 Check wigwag an
6. Step 9 Similarly When you filter the top 3 items look at the column L Time passed from Release date Step 10 There will be some values listed in column L Step 11 Select those values and find its average Step 12 Do the same for top 3 items Step 13 Make that average value as the values in Y Axis Step 14 Draw the Pareto Chart Step 15 Repeat the same for 25 not 15 and 35 not 25 Step 16 For Lazy Reports Repeat the steps from 1 TO 14 Step 17 It is applicable for all 4 lazy reports Step 18 For 25 not 35 the only change is in Y Axis values Step 19 Instead of going to column Time passed from release date Go to Time passed after operation 25 Step 20 Draw Pareto Chart 2010 Millennium Infologic All rights reserved Millennium University 2 3 Daily Check Lists Small Press Big Press Chromojet and Crumb Routine DAILY CHECK LISTS for Big Press 2010 Millennium Infologic All rights reserved Millennium University 2010 Millennium Infologic All rights reserved Millennium University 1st Shift 2nd Shift TASK P5 Check extruder temperature Sterlco should be at 165 degrees IP6 Check extruder temperature Sterlco should be at 165 degrees P5 Ensure wig wag rubber edge strip and base sheet are staged for the days production P6 Ensure wig wag rubber edge strip and base sheet are staged for the days production P5 Check if operator is cycling empty molds through press
7. open it Step 79 Open Macola MM gt Shop floor control gt View gt Shop order Status on screen Shop order status view new window in macola Step 80 Copy the shop order number in column J from the spreadsheet Step 81 Paste it in starting shop order number and ending shop order number in macola Step 82 Press Tab until the result get displayed in macola Step 83 Press Enter on screen Shop order info a new window in macola Step 84 Click on operation tab Step 85 See the result displayed in Macola Note It shows which all operations are there in this particular order Also see the planned quantity and Actual quantity Step 86 Verify whether the Planned Quantity is same as that of Actual Quantity 2010 Millennium Infologic All rights reserved Millennium University Step 87 If not add it as a comment in the spreadsheet Step 88 Check the operation number in macola and if one operation is missing mention that as a comment in the spreadsheet Note For example If the operation 35 is not present then write comment as Not Applicable in the spreadsheet Step 89 Check the operation number in macola and if one operation is present but it is not completed Then mention that it is not done in spreadsheet Note For example If the operation 35 is present then write comment as Not Done in the spreadsheet Step 90 Go to Macola gt Shop floor Control gt Reports and Graphs gt Activity History gt
8. or watch unloader loader time Is the press cycle on schedule 1 00 PM P5 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed P6 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners 12 00 AM P5 Check trimming operation Make sure the trimming is being performed to the work instructions 1 30 PM P6 Check trimming operation Make sure the trimming is being performed to the work instructions P5 amp P6 Check perforating and mat rolling operation Ensure it is being performed according to work instructions P5 amp P6 Check logo matching and rolling to ensure it is being done on time P5 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out P5 Check the amount of rubber on the edge strip robot Ensure roll has enough rubber and does not need 12 30 AM 2 00 PM P5 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out P6 Check the amount of rubber on the edge strip robot Ensure
9. out to be changed 7 00 PM P6 Check the amount of rubber on the edge strip robot Ensure roll has enough rubber and does not need to be changed P5 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out P6 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out P5 Check shop order transactions performed on scheduled items note where they are at on the schedule P6 Check shop order transactions performed on scheduled items note where they are at on the schedule 8 30 AM 6 Check computer rubber dimensions from extruder operator and ensure they are in spec P5 Check amount of time it takes for the robot to wait for the rubber Must be 14 seconds or less for 3x10 a 6 Check amount of time it takes for the robot to wait for the rubber Must be under 7 seconds P5 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the o W press cycle on schedule m 9 00 AM P mats are being brushed properly if needed P6 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure See mats are being brushed properly if needed 2010 Nillennium Infologic All rights reserved P5 Check coverage in all positions due to break time on the lines P6 Check coverage in all positions due to break time on the lines P5 Check compu
10. pdf Step 4 Open the Downtime login file production_downtime_date xls from share folder Step 5 Go to coulmn comments amp see the time Starting shift time and ending shift time Step 6 Calculate Run Time Ending shift time Starting shift time Step 7 Now go to template and to input tab Step 8 Based on the shop floor order xls file from kevan note down the carpet size Step 9 Go to input tab again enter the calculated Run time value in corresponding column for carpet size Step 10 Now go to EOS pdf file and navigate to a table with EOS as header Step 11 Note down the value near the row header open35 standards That value will be the total number of mats produced Step 12 Go to P and L template navigate to mats produced column Step 13 Enter the total number of mats produced in the corresponding date and corresponding type of mats produced Step 14 Go to the EOS pdf again navigate and find the Resource report header Step 15 Find note down the total value in row as Rubber and Carpet as header Step 16 Go back to P and L template go to materials column enter the total value of rubber abd carpet in the corresponding date column Step 17 Go back to EOS pdf file navigate to the table with header miscelleneous resources and find the total values for each material 2010 Millennium Infologic All rights reserved Millennium University Step 18 Go back to P and L template and go to expense col
11. rights reserved Millennium University DAILY CHECK LISTS for Small Press 2010 Millennium Infologic All rights reserved Millennium University 1st Shift 2nd Shift TASK Ensure edge strip bead and base sheet are staged for the days production specification 4 30 a m Ensure all tools for production are available gloves scissors bolt adjustors cleaning tools hand truck etc Note missing items in the comments 3 30 PM Ensure the proper carpet is staged for the scheduled shop orders Check build on mold Check overlap of edge strip Check bead placement Check carpet placement Check amount of mats per cycle Note any empty zones Check mat removal Ensure embosses are being collected and returned to builders Ensure there are enough partners to maintain the flow of the line 13 max including trimmers Check base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out Check edge strip supply Ensure the correct sizes and compounds are staged so the machine will not run out 4 00 PM Check bead supply Ensure the correct compounds are staged so the machine will not run out 5 00 AM 5 30 AM Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule Check the number of times the equipment has bee
12. roll has enough rubber and does not need to be changed P6 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out P5 Check shop order transactions performed on scheduled items note where they are at on the schedule P6 Check shop order transactions performed on scheduled items note where they are at on the schedule P i A P i P5 Check amount of time it takes for the robot to wait for the rubber Must be 14 seconds or less for 3x10 and under 7 seconds for 85x150 euro 1 00 AM P5 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule P6 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule 2 30 PM P5 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed P6 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed 2010 Millennium Infologic All rights reserved 2 45 PM to 3 15 PM Millennium University P5 1st shift Ensure second shift extruders have logged in for the day and are updating documents checking the material and preparing for the day P6 1st shift Ensure second shift extruders have logged in for the day and are updating documents
13. schedules and plan for pit stops 7 30 AM E Determine how many liters of dye will be disposed of based on expiration date and record Check that drums are being thoroughly washed out Did you find any other issues affecting productivity Record additional comments gt gt ex 2010 Millennium Infologic All rights reserved Millennium University 8 00 AM Check housekeeping and correct any issues immediatel Did you find any other issues affecting productivity Record additional comments gt gt AD Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Check with trimmers for rejects and quality issues 7 30 PM 8 30 AM Know the estimated run times for the current schedules and plan for pit stops Check amount of scrap coming off each Chromojet 9 00 AM Check housekeeping and correct any issues immediatel Check filters Note how many were changed and which pumps have been changed Check jets Note how many were changed and which jets have been changed Did you find any other issues affecting productivity Record additional comments gt gt DE Check to see that there is adequate foaming in the steamer Verify correct penetration per schedule and monitor closely throughout the day Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Has the jet technician picked up bad jets he
14. 12 While cross checking If the copied value is not there in the printed list then add a comment NOT FOUND in the remarks column Step 13 Repeat the same for CJET B and CJET C Step 14 Do the steps from Step 1 to Step 13 for 2 shift as well Step 15 Now open CJET A in Chromojet EOS xls and copy all the values which has NOT FOUND in the remarks column and paste it in a new spreadhseet to send to 2010 Millennium Infologic All rights reserved Millennium University Janice Jim Kevan etc Step 16 Repeat the same for CJET B and CJET C Part 2 CJ Transaction Step 1 Open Chromojet EOS xls and cj_txn_date xls template Step 2 Copy all the values under Schedules in CJET A CJET B and CJET C tab in Chromojet EOS xls Step 3 Paste the copied values in cj_txn_date xls under the respective schedules Step 4 Log on to the Citrix and open the access file Checkalltransaction mdb on screen Missing Macola Transaction Step 5 Enter the Name and Schedule copy the schedule from the cj_txn_date xls Step 6 Click Chromojet button on screen rptmissingtrxCROM window Note The list displayed in the window will be empty if all transactions are closed If not there will be orders listed Step 7 Copy the SFOrder from the list Step 8 Go to Macola gt Shopfloor Control gt View gt Shop order status on screen Shop Order Status View Step 9 Paste the SFOrder in Starting shop order no and ending shop order n
15. 35 Enter the daily budget as 7 column Step 36 Based on the standard calculation in calculation tab of P and L template enter your analysis comment as Good Average Below Average 2010 Millennium Infologic All rights reserved Millennium University Step 37 Enter the comments in the last column of press 5 6 tab of daily target MMYY xls if any Part 2 Crumb Routine Repeat steps I to 37 Part 3 For Small press Step 1 Upon Receiving EOS pdf End of Shift file from Janice download the same from your mail box Step 2 Open the P and L template from W Shared MILControl Room PandLtemplate Step 3 Open the template to enter the values you got from pdf Step 4 Open the Downtime login file production downtime date xls from share folder Step 5 Go to coulmn comments amp see the time Starting shift time and ending shift time Step 6 Calculate Run Time Ending shift time Starting shift time Step 7 Now go to template and to input tab Step 8 Based on the shop floor order xls file from kevan note down the carpet size Step 9 Go to input tab again enter the calculated Run time value in corresponding column for carpet size Step 10 Now go to EOS pdf file and navigate to a table with EOS as header Step 11 Note down the value near the row header open35 standards That value will be the total number of mats produced Step 12 Go to P and L template navigate to mats produced column Step 13 Ente
16. Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule P6 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule P5 Check the number of times the equipment has been put in manual mode IP6 Check the number of times the equipment has been put in manual mode P5 Check previous shifts press transactions on shop orders Ensure all Shop Orders are transacted using 6 00 Am 4 30 PM ithe correct operation number SPEC OPER 002 P6 Check previous shifts press transactions on shop orders Ensure all Shop Orders are transacted using the correct operation number SPEC OPER 002 P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners 6 30 AM 5 00 PM P5 Check trimming operation Make sure the trimming is being performed to the work instructions P6 Check trimming operation Ensure trimmer stations are filled with incoming partners quickly and that they are prepared for the day Ensure trimming is being done according to work instruction P6 Check trimming operation Ensure trimmer stations are filled with incoming partners quickly and that they are prepared for the day Ensure trimming is being done accordi
17. ISIANA STATE UNIVERSITY Pou Date 08713718 fore ivoa No 531707 RMA No Fe Pre 5 500008 Item No Oty Ordered Qty Shipped Ext Price kee a eooo 6773 36 0008 36 0000 198 000000 D Les MT Toll Qh Ta ege Total Amt 198 06 Comments Billing Blorke Se Oger Header Receiving Comments Order No 420982 Order Date 92779770 Cust No 6533 ur BOOKSTORE INC C26 775 Weight Lbs Declined Value Harding Charge COD Amount Tea owof o oo O on i Freight Post Ship Date Carries Mode Trace No IERT FEDEX fE 63098730015070 4 87 F 08 04 10 FedEx G 363098730015070 Step 70 Click on each item one by one First click the first item in the list Step 71 Click Billing button 2010 Millennium Infologic All rights reserved Millennium University on screen Order billing info view Step 71 Click Ship tex button Step 72 Check whether the items get displayed in Macola Note This shows the status whether the item is shipped or not Step 73 If not a pop up No shipping charges for this order will get displayed Step 74 For such orders go back to spreadsheet and put it not shipped billed in remarks column Note Check transaction history in macola and put the comment in spreadsheet Step 75 Go and open the Lazy report ended Step 76 Repeat steps 65 to steps 74 Step 77 Write comment not billed in the remarks column If that particluar order is not billed Step 78 Hop and open Lazy report started and
18. Millennium University Millennium University ID 2010 Millennium Infologic All rights reserved Millennium University About Millennium Infologic Millennium Infologic MIL is a IT solutions and IT enabled services firm based in Cochin Infopark Kerala India We concentrate on customer oriented services in diverse fields which include Order Processing Graphics Market Research Remote desktop management Remote control room monitoring Software Development and Web and Accounts About our parent company Millennium Mats Since opening production in August 1999 Millennium Mat Company Guardian Floor Protection has grown to become one of the largest mat manufacturing operations in the world Millennium Mats have been able to continually invest in innovative technology and manufacturing methods that create quality products with cost effective floor protection solutions In our world class 2 50 000 sqaure foot manufacturing facility along with our research and development team we have been able to develop many new products while enhancing our purchasing portals streamlining our order automation and reducing product costs This was possible all from the feedback of our valued customers Millennium s most important goal is one that is ongoing To understand the ever growing needs of our customers Millennium strives to constantly improve our prodcuts systems and services to meet the challenges of working with the world s f
19. RES 138 WI OPER 003 PR transact and for shop orders Rue E S complete orders gt WI OPER 003 WEPRES 130 WLPRES 134 otk SPEC OPER 002 SC FORM PRES 135 FORM PRES 136 2010 Millennium Infologic All rights reserved
20. Status started Labor Tre Rem No 396 ARIZONA STATE UNIVERSITY Mater Tm col FOOTBALL o o S Sep ntion Order Qty 3 0060 Complete Qty 8 0080 Note Job Info WC Load Code o oper Cycles Per Hr zl Oper Type P Productive Kai Oper Description Dept Work Center Cnt Prt PRINT Rom cRomoJET am d F Notes Found _ Oper No Planned Oty Actual Oty Planned Hrs Actual Hrs it 1s not sf 3 666067 3 e000 6 199998 1 800000 5 3 6666 3 6666 8 199998 1 666666 15 3 6668 4 6066 6 399996 2 666666 25 3 6668 3 6668 1 446666 1 666666 35 3 66668 6 6666 6 699999 6 666666 I ry gt By on screen Activity by shop order report 2010 Millennium Infologic All rights reserved Millennium University GER File Ed Window Heb Staiting Parent Item No ALL Ending Patent ltem No Stating Shop Order No 845251 E Ending Shop Cider No 945251 al Shop Order Selection Statling Transaction Date aLL Ending Transaction Date rint Options User FESR Repoit SFACPRT Print To Screeri C Fie C Painter F Dele Pinra Printer Defauke Pie AP Deskjet Fh106 series from WI FEuCGHZ4ZN7zyLhxg Paper Ketter Step 27 Paste the shop order number in the corresponding place in macola Step 28 Click OK button Step 29 Select option screen and press OK on screen Activity history report Note Now you can see the current status of each operation Step 30 Note down the date and put the same in
21. T tab of daily target MMYY xls Step 35 Enter the daily budget as 7 column 2010 Millennium Infologic All rights reserved Millennium University Step 36 Based on the standard calculation in calculation tab of P and L template enter your analysis comment as Good Average Below Average Step 37 Enter the comments in the last column of press CJET tab of daily target MMYY xls if any 2010 Millennium Infologic All rights reserved Millennium University 3 Press Process Flow Diagram 2010 Millennium Infologic All rights reserved Millennium University WI PRES 001 Quality Assurance Builder See SE fandard and Logo Press MGR Mat Puller ae Treadlock Cintas Mats Euro Mats wee 3x7 and 3x10 3x5 Press Lead Trimmer Inspector Ye P 5 Workfl 3x10 oF 3x5 Extruder Operator Counter Transaction Coordinator f ress UO Pit Crew Builder Roller Standard and Logo Mat ES eg Bead Edge Strip Crumb Rubber Materials set upline based Machi t Mold After the rubber Shop orders are Planned sc
22. ake sure 6 Check amount of time it takes for the robot to wait for the rubber Must be under 7 seconds P5 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the D P6 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule 7 30 AM 5 Check the number of times the equipment has been put in manual mode the robot to wait for the rubber Must be 14 sec mats are being brushed properly if needed P6 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners 6 30 PM P5 Check trimming operation Make sure the trimming is being performed to the work instructions P P6 Check the number of times the equipment has been put in manual mode P D 8 00 AM P6 Check trimming operation Make sure the trimming is being performed to the work instructions P5 amp P6 Check perforating and mat rolling operation Ensure it is being performed according to work instructions P5 amp P6 Check logo matching and rolling to ensure it is being done on time machine will not run out machine will not run
23. aying mold release on every mold QA partner is vacuuming off excess crumb JQA partner fills in if there is a vacant space in the corner Lead should notified for large space JQA partner must use spreader bar to spread the crumb evenly across the mold Blue specs are not on corner and edge molds JQA must use very good condition paper on the mold no tears in paper QA partner must vacuum the cross bars of the comer and edge molds Jaspers being removed as the molds come out of the hot press _ Operator is using T square to cut mat in half at the exit of the hot press __ lf operator does not use T square Lead must be notified D Mat is being removed by folding in half as it comes off of the mold unless it is an edge corner mold __ stack of mats that are finished do not exceed 1 meter high cooling issues 7 00PM _ Mat specs are checked and called in it will range from 335 to 385 inches Settings are checked Weight of crumb in each drum is checked it should be 50 2 En mount of binder is checked 2010 Millennium Infologic All rights reserved 9 00 AM 9 30 AM 10 00 AM 10 30 AM 11 00 PM 11 30 PM 12 30 PM 1 00 PM 1 30 PM Millennium University 7 30 PM Check Settings Temp should be 280 degrees pressure 90 psi time should be 400 sec Check number of molds should have a minimum of 18 Check the number of usable platens Should be only 6
24. chine will not run out heck bead supply Ensure the correct compounds are staged so the machine will not run out heck carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out heck shop order transactions performed on scheduled items note where they are at on the schedule Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule heck the number of times the equipment has been put in manual mode heck amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed heck build on mold Check overlap of edge strip Check bead placement Check carpet placement heck amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed heck logo matching and rolling to ensure it is being done on time heck amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule heck the number of times the equipment has been put in manual mode heck amount of mats p
25. ck and note the last time the vacuum hose was changed 9 45 a m heck transactions from the morning heck that the vacuum head is operational heck with trimmers for rejects and quality issues now the estimated run times for the current schedules and plan for pit stops 8 30 PM heck the reprint log for possible late and lost reprints heck amount of scrap coming off each Chromojet 9 30 AM 10 00 AM Check housekeeping and correct any issues immediatel Did you find any other issues affecting productivity Record additional comments gt gt Know the estimated run times for the current schedules and plan for pit stops Check for temperature of the dryer on each c j Check for no jet leaks or white lines 9 00 PM Check to see that the steamer temperature is set correctl 10 30 AM Verify correct penetration per schedule and monitor closely throughout the da Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Check with trimmers for rejects and quality issues Know the estimated run times for the current schedules and plan for pit stops Check amount of scrap coming off each Chromojet Check housekeeping and correct any issues immediately 11 00 AM Check filters Note how many were changed and which pumps have been changed Check jets Note how many were changed and which jets have been changed Did you find any other issues affecting productivity Record additio
26. corresponding column in spreadsheet Step 31 Go back to Frm Transaction Table and click 25 not 15 Step 32 Repeat steps from 5 to 30 Step 33 Go back to Frm Transaction Table and click 35 not 25 Step 34 Repeat steps from 5 to 30 Note In 25 not 15 and 35 not 25 spreadsheets add an additional column Time passed shipping date only if the order crossed the deadline Step 35 Go back to Frm Transaction Table and hit 5 not 15 button 2010 Millennium Infologic All rights reserved Millennium University on screen 5 not 15 Table Step 36 Export the table to a spreadsheet and make the alignment proper Step 37 Go to the spreadsheet and see the column Time passed Step 38 Edit that column header and change it to Time passed after operation 25 Step 39 Add a column Time passed from release date after the previous column Step 40 Put the formula Checking date Order Date in Time passed from release date column and drag the formula till bottom Step 41 Add column Time passed from shipping date Step 42 Put formula Checking date Shipping date and drag the same till bottom Step 43 Go back to Frm Transaction Table and hit 15 not 25 button Step 44 Repeat the steps from 36 to 42 Step 45 Go back to Frm Transaction Table and hit 25 not 35 button Step 46 Repeat the steps from 36 to 42 Step 47 Go back to Frm Transaction Table and hit Release button Step 48 Export the table to a spreadshee
27. d base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out P5 Check the amount of rubber on the edge strip robot Ensure roll has enough rubber and does not need 11 00 PM P6 Check the amount of rubber on the edge strip robot Ensure roll has enough rubber and does not need 11 00 PM 12 30 PM P5 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not P6 Check carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not 5 Check shop order transactions performed on scheduled items note where they are at on the schedule P6 Check shop order transactions performed on scheduled items note where they are at on the schedule DIOL AT ig reserveu JE Se ae alo CD IC ioo io amp US Qjo Cla gt 213 D OM 3 Old a Aka OD 10 CO elt Millennium University P5 Check computer rubber dimensions from extruder operator and ensure they are in spec P6 Check computer rubber dimensions from extruder operator and ensure they are in spec 11 30 PM P5 Check amount of time it takes for the robot to wait for the rubber Must be 14 seconds or less for 3x10 and under 7 seconds for 85x150 euro P5 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule P6 Check wonderware and note any delay in cycle times Use trend
28. dentify quality and potential quality issues identifies variations of machine settings and assist maintenance in rapid troubleshooting of problem 1 2 Work Flow Diagram 2010 Millennium Infologic All rights reserved Millennium University CHAPTER2 USER MANUAL INSTRUCTIONS 2010 Millennium Infologic All rights reserved Millennium University 2 1 Task CJ Transaction and CJ Schedule Updation Part 1 CJ Schedule Updation Step 1 Upon Receiving EOS and Schedule list from Janice Kevin for 1 and 2 shift Step 2 Open Chromojet EOS xls and CJET Shift Schedule xls Step 3 First open Chromojet EOS xls and go to column with header Schedules on screen Chromojet EOS xIs Step 4 Copy a list of data in CJET A CJET B and CJET C under Schedules Step 5 Copy all the data in the CJET A and go and paste it in CJET Shift Schedule xls tab A Step 6 Add 2 columns Shift 1 and Remarks under the already printed schedules on screen CJET_Shift_Schedule xls Step 7 Paste the copied values under Shift 1 Step 8 Repeat the same for CJET B and CJET C Step 9 Now Cross check whether the copied values are already there in the earlier listed already printed schedules using Control F Step 10 If the values are already in the already printed list the go to that value in the printed list and color it Red Color and Blue Background Step 11 And Remove that value from the copied list Step
29. designated distorting the P oyde onto the mold pallet rubber Kai Note bad platens Are all platens No Are there 2 or fewer WA Stop production on white board available platens cancelled and fix press for maintenance P to fix after the endof the shift Yes Yes 4 After 30 out of Releases mold Mat Press opens and the hot press he Loader transfers Pressure tine and Unkager wil Mat puller Lifts edge and Sets mat edge is removed by mold Mat transfers on belt loader should start temp parameters start releasing inspects per checks emboss molds start to pull until the entire load Press closes gt onthe top gt advancing under to platform next to out of hot press enieringas ong at is fully in the press aus nee melts one a cn replaces if conveyor same conveyor trim tables H ithas all platens d p specification a time sheet necessary y Baeske We accounted for SS SPEC PRES 104 WI PRES 128 Press 5 Map Mat Trimmer 1 lifts Trimmer 2 unfolds Trimmer 3 trims last Paso a aie gl it ae Mats tak en to Final and trims short edge and trims long edge LA long edge folds and Is ita logo No send onbelt with like sizes and shop orders for Quality Audit Station of mat Passes mat Passes mat to trims last short matroller colors Stacks logos standard mat and to Shipping to Trimmer 2 Trimmer 3 edge e logo Ge pallets after Passed audit Stack on pallet or but e sortin separate WI PRES 132 Yes piles for Counter to Ales WIPRES 137 WI P
30. ed to MM date column Step 59 Go to column Time passed from shipping date and put the formula Checking date Released date Step 60 Drag both the above formula till the bottom Step 61 Filter the column Order Status and split it and save as 4 different spreadsheets Filter it by CLOSED C Filter it by STARTED S Filter it by RELEASED R Filter it by ENDED E Step 62 Save the above 4 spreadsheets and name it as Lazy reports closed Lazy reports started Lazy reports released Lazy reports ended respectively 2010 Millennium Infologic All rights reserved Millennium University Step 63 Go to Lazy Report Released and see whether all column values are correct Step 64 Go to Lazy Report Closed and open it Step 65 Go to Macola FM gt Order Entry gt View gt Order View Order History gt By order no on screen Order View by Order no Step 66 Copy Order Number from Spreadsheet and paste it in order no in Macola Step 67 Press tab util result get displayed Step 68 Check whether the order is invoiced by looking at invoice no column in macola Step 69 Press Enter to see the report Note List of Items displayed Order Entry History View EEN Ext Ore 420942 Cust 6533 Coop BOOKSTORE INC Cunt Wees Tax Scheduls Disc Pa Tavan Unit Cost 2 500000 ln ReqDate 07709710 Bi Dae 08 12 10 UOM Es Loc oui Fannars wi Rea Shp Date Invoice Date 08 12 18 Raio 7 00000 PO S7636 Pick PackDete 77377 PrmseDote 67 00 18 LOU
31. ement heck trimming operation Make sure the trimming is being performed to the work instructions 8 00 AM 6 30 PM Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule heck amount of mats per cycle Note any empty zones heck base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out heck edge strip supply Ensure the correct sizes and compounds are staged so the machine will not run out 8 30 AM 7 00 PM heck bead supply Ensure the correct compounds are staged so the machine will not run out heck carpet supply Ensure the carpet is the correct size style and color Ensure the machine will not run out heck shop order transactions performed on scheduled items note where they are at on the schedule 9 00 AM 7 30 PM unch Check coverage in all positions due to break time on the lines Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule 10 00 AM 8 30 PM heck the number of times the equipment has been put in manual mode heck amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed heck build on mold Check overlap of edge strip Check bead placement Check carpet placement 10 30 AM ee and note any delay in cycle times Use trend or watch
32. er cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed heck shop order transactions performed on scheduled items note where they are at on the schedule nsure lead has completed end of shift documents nsure all screens and presses are emptied nsure all screens are cleaned nsure partners finish trimming remaining mats and finish rolling and stacking nsure trim area is cleaned and organized Ensure Trimmers and Rollers have gone by 2 30 am mi mim MIO IS 2 g an D S bt S bd S lt D z S b D S 2 D D Ep bi bg D D 2 a Q Gs D 2 N D Q Ki bd Ss a o 9 a D lt 2010 Millennium Infologic All rights reserved Millennium University DAILY CHECK LISTS for CHROMOJET 2010 Millennium Infologic All rights reserved Millennium University SHIFT circle one dst Lang heck which jets were calibrated from the night before and record pump number heck that all Chromojet machines are on and warming up heck schedules to make sure proper carpet is loaded for schedule heck that both steamers pressure and temperature are set correctl heck that presteamer is on if required and carpet is in up most position est one color Note color viscosity and pH in comments est one more color Note color viscosity and pH in comments heck that all colors are loaded correctl heck tha
33. f needed Check filters Note how many were changed and which pumps have been changed Check jets Note how many were changed and which jets have been changed Did you find any other issues affecting productivity Record additional comments gt gt 12 00 AM Verify correct penetration per schedule and monitor closely throughout the da Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Did you find any other issues affecting productivity Record additional comments gt gt Housekeeping no carpet on floor no clutter soft waste neatly stacked Know the estimated run times for the current schedules and plan for pit stops Check for temperature of the dryer on each c j Check for no jet leaks or white lines Check to see that the steamer temperature is set correctly Verify correct penetration per schedule and monitor closely throughout the day Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Housekeeping no carpet on floor no clutter soft waste neatly stacked Make sure scrap is weighed and recorded Check for misc clutter around the Chromojets and correct immediatel Make sure any reprints needed to complete the days orders are scheduled Check filters Note how many were changed and which pumps have been changed Check jets Note how many were changed and which jets have been chan
34. ged Check that all pallets are in place Complete end of shift paperwork and turn in to supervisor manager Make sure all printing transactions have been entered for schedules printed on the shift Provide informative feedback to oncoming shift Know the estimated run times for the current schedules and plan for pit stops Check that the size of the trimmed carpets are within specification Check the reprint log for possible late and lost reprints 12 30 AM 1 Record pit crew times in comment section the half hour they happen 2 Verify color squares are inspected by quality during a pit stop 3 Verify setting for the steamer and dryer are set properly after every pit 4 Any pauses or machine stop have to be noticed and recorded in the time that it occurs 2010 Millennium Infologic All rights reserved Millennium University DAILY CHECK LISTS for CRUMB ROUTINE 2010 Millennium Infologic All rights reserved START UP TIME 1st Shift 4 30 AM 5 00 AM 5 30 AM 6 00 AM 6 30 AM 7 00 AM 7 30 AM 8 00 AM 8 30 AM Millennium University 2nd Shift TASK 3 30 PM Check Settings Temp should be 280 degrees pressure 90 psi time should be 400 sec Check number of molds should have a minimum of 18 Check the number of usable platens Should be only 6 mods have to be warmed Blue fence has to be taken down D Haw lead check for feed stops and the knife is at it s proper height 4 00PM Corner
35. hedule is on the schedule and P acne is se mice ere meets specified prepared by the set up in order of inventory is taken of the ee kad ii we Weg with paer cycled d ne ee 3 We criteria itis placed val R eae planning run and kept in the items designated to press 5 ana et Seppe proper PO better weern on molds by rubber ue raw materials areas designated the product that is under proper start up checklist robot department control room and noted on the material toberan condifons robot within marked log sheet i perimeters WIPRES 108 WIPRES 104 WI PRES 106 WI PRES 110 WI PRES 111 FORWEMAN 001 FORM PRES 108 Li SPEC PRES 104 WLPRES 127 FORM PRES 110 FORM PRES 111A Gs ES x GC B FORM PRES 1118 ZT gor a Sg Kom SZ SS eege Ss SPEC PRES 109 WI PRES 113 TN Robot pl Edge strip robot picks up 4 ta d Mats are checked for strips and places 2 strips on Ae Moldad Robot cuts carpet to e d proper edge strip one mat and saves 2 strips te a No os ne proper specified e be Mold advances to 5 it alogo No placement proper carpet Mat goes into for the next mat The the schedule a ue t length using houl d QA 990 placement carpet quality loader overlap cannot exceed 14 Ds ER ultrasonic cutting Se inspection no empty molds centered on and must be centered etc edges MEERES Me Ml WEPRES 124 t FORM PRES 126 WEPRES 118 WEPRES 123 Garen y ARS we oy Remove cut Place label Shop orders begun Place logo carpet and under rubber cen La LE designated pallet
36. iew new window in macola d Prooresann workitow Er a u Fie Ee View Progam Corgany O MLLENAUIMMAT ook Aire Wixhe Help I SESS le arc rie Si BR 10 xi Gi 3 Shep Flooi Cental BE J View P Shop Ondes Statut P Orire Oicpatcher P Pa Due Ordas i P Tid Alocation Ending Job Ni al tore D Bem H a 3 AP Mukipile Level Fon S EE ka E i og P Stock Saui Starting Shop Order No fra L ia Starting Due Date fat Were Master To pe d A Caden Ending Shop Order No fw Erding Due Date E E L Work Center ScPkg S de Parentitem Na Customer No I Reverse Order View e Labor j Oe DE fam bon Vie PL Equemeet Tod E S Tre tona Des _ Stat Date Planned diy E IJ Procecser a SS SSS E L Reports AR s One item No Order Sistus Dun Dao Google Step 16 Copy the shop order number in column J from the spreadsheet Step 17 Paste it in starting shop order number and ending shop order number in macola 2010 Millennium Infologic All rights reserved Millennium University Step 18 Press Tab until the result get displayed in macola Step 19 Press Enter on screen Shop order info a new window in macola Step 20 Click on operation tab Step 21 See the result displayed in Macola Note It shows which all operations are there in this particular order Also see the planned quantity and Actual quantity Step 22 Verify whether the Planned Quantity is same as that of Actual Quantity Order No 545898 Order
37. inest companies 2010 Millennium Infologic All rights reserved Millennium University Foreword To The Control Room Team Millennium Infologic We The Millennium University are pleased to launch a Control Room Manual at Millennium Infologic which would serve as a ready reckoner for all the control room activities The Control Room Manual incorporates the procedures which are required on a regular basis to process the tasks and to handle the partner queries better It is also intended to provide guidelines to develop and maintain a supportive environment for your team This is our first endeavor and we would look forward to your feedback to further fine tune the Manual Wish you the very best Deepak E V 2010 Millennium Infologic All rights reserved Millennium University Summary The Control Room operators monitor production operations on all equipment in the plant They identify machine slow down events and notify the appropriate supervisor or lead of the occurrence They also identify properly record events that cause slow down or down time After that they analyze and report the data to the management staff The Team Identifies process and procedure variances and improvements And Properly record the variances and report to the management staff They identify quality and potential quality issues that can be seen from the control room Like for other errors they properly record the issues and rep
38. ing day Step 27 Enter that value as second column in press 2 4 tab of daily target MMY Y xls Step 28 Enter the Total labor cost from P and L template and enter it as 3 column of press 2 4 tab of daily target MMYY xls Step 29 Get the Downtime value from production downtime xls Step 30 Enter the Downtime values as 4 column of press 2 4 tab of daily target MMYY xls Step 31 Get the Extra material cost value from P and L template input tab Step 32 Now enter extra material cost value in 5 column of press 2 4 tab of daily target MMYY xls Step 33 Now go to EOS pdf and go to table with header EOS report and get the scrap and reworks value Step 34 Enter those values as 6 column of press 2 4 tab of daily target MMYY xls Step 35 Enter the daily budget as 7 column 2010 Millennium Infologic All rights reserved Millennium University Step 36 Based on the standard calculation in calculation tab of P and L template enter your analysis comment as Good Average Below Average Step 37 Enter the comments in the last column of press 2 4 tab of daily target MMYY xls if any Part 4 For Chromojet Shift 1 and Shift 2 Step 1 Upon Receiving EOS pdf End of Shift file from Mark download the same from your mail box Step 2 Open the P and L template from W Shared MILControl Room PandLtemplate Step 3 Open the template to enter the values you got from pdf Step 4 Open the Downtime login file productio
39. man is spraying mold release on every mold JQA partner is vacuuming off excess crumb QA partner fills in if there is a vacant space in the corner Lead should notified for large space QA partner must use spreader bar to spread the crumb evenly across the mold D Blue specs are not on corner and edge molds QA must use very good condition paper on the mold no tears in paper QA partner must vacuum the cross bars of the corner and edge molds 4 30PM _ Paper is being removed as the molds come out of the hot press Operator is using T square to cut mat in half at the exit of the hot press __ lf operator does not use T square Lead must be notified Mat is being removed by folding in half as it comes off of the mold unless it is an edge corner mold Jstack of mats that are finished do not exceed 1 meter high cooling issues 5 00PM _ Mat specs are checked and called in it will range from 335 to 385 inches Settings are checked Weight of crumb in each drum is checked it should be 50 2 LE Jamount of binder is checked make sure there is at least 2 bags of crumb staged 5 30PM Check Settings Temp should be 280 degrees pressure 90 psi time should be 400 sec Check number of molds should have a minimum of 18 1 Check the number of usable platens Should be only 6 mode have to be warmed Blue fence has to be taken down jHaw lead check for feed stops and the knife is at it s proper height 6 00PM _ Corner man is spr
40. mber of usable platens Should be only 6 mode have to be warmed _ Blue fence has to be taken down Ha lead check for feed stops and the knife is at it s proper height 10 00 PM BREAK 11 00 PM Mat specs are checked and called in it will range from 335 to 385 inches Settings are checked Weight of crumb in each drum is checked it should be 50 2 Jamount of binder is checked make sure there is at least 2 bags of crumb staged 11 30PM Check Settings Temp should be 280 degrees pressure 90 psi time should be 400 sec Check number of molds should have a minimum of 18 Check the number of usable platens Should be only 6 molds have to be warmed D _ Blue fence has to be taken down Have lead check for feed stops and the knife is at it s proper height Corner man is spraying mold release on every mold 12 00 AM Corner man is spraying mold release on every mold QA partner is vacuuming off excess crumb 1 JOA partner fills in if there is a vacant space in the comer Lead should notified for large space D QA partner must use spreader bar to spread the crumb evenly across the mold Blue specs are not on corner and edge molds QA must use very good condition paper on the mold no tears in paper QA partner must vacuum the cross bars of the comer and edge molds 2010 Millennium Infologic All rights reserved Millennium University 2 00 PM 12 30 AM Paper is being removed as the molds come out
41. mods have to be warmed he fence has to be taken down Have lead check for feed stops and the knife is at it s proper height 8 00 PM_ Corner man is spraying mold release on every mold D QA partner is vacuuming off excess crumb QA partner fills in if there is a vacant space in the corner Lead should notified for large space JQA partner must use spreader bar to spread the crumb evenly across the mold Blue specs are not on corner and edge molds JQA must use very good condition paper on the mold no tears in paper QA partner must vacuum the cross bars of the comer and edge molds Er 8 30PM Paper is being removed as the molds come out of the hot press Operator is using T square to cut mat in half at the exit of the hot press __ If operator does not use T square Lead must be notified Mats being removed by folding in half as it comes off of the mold unless it is an edge corner mold Jstack of mats that are finished do not exceed 1 meter high cooling issues 9 00PM _ Mat specs are checked and called in it will range from 335 to 385 inches LU Settings are checked Weight of crumb in each drum is checked it should be 50 2 mount of binder is checked make sure there is at least 2 bags of crumb staged 9 30 PM_ Check Settings Temp should be 280 degrees pressure 90 psi time should be 400 sec Check number of molds should have a minimum of 18 1 Check the nu
42. n Step 19 Go back to EOS pdf file and navigate to the table with header Total labor hours Step 20 Note down the total labor hours Step 21 Go back to P and L template and go to labor coulmn and enter the labor cost in the corresponding day s coulmn Step 22 Go to P and L tab in the P and L template Note There you could see total output of all entered values in the input tab Step 23 Now open a new spreadsheet and name it as daily target MMYY xls Step 24 Name a new tab as Press CJET shift 1 shift 2 for CJET Step 25 Enter the current date in first column Step 26 Upon receiving square meter values from Simona note down SQM values and enter it in Mats produced column of P and L template under corresponding day Step 27 Enter that value as second column in press CJET ab of daily target MMYY xls Step 28 Enter the Total labor cost from P and L template and enter it as 3 column of press CJET tab of daily target MMYY xls Step 29 Get the Downtime value from production downtime xls Step 30 Enter the Downtime values as 4 column of press CJET tab of daily target MMYY xls Step 31 Get the Extra material cost value from P and L template input tab Step 32 Now enter extra material cost value in 5 column of press CJET tab of daily target MMYY xls Step 33 Now go to EOS pdf and go to table with header EOS report and get the scrap and reworks value Step 34 Enter those values as 6 column of press CJE
43. n put in manual mode 6 00 AM 4 30 PM Check previous shifts press transactions on shop orders Ensure all Shop Orders are transacted using the correct operation number SPEC OPER 002 Check build on mold Check overlap of edge strip Check bead placement Check carpet placement Check trimming operation Ensure trimmer stations are filled with incoming partners quickly and that they are prepared for the 6 30 AM 5 00 PM day Ensure trimming is being done according to work instruction Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule Check logo matching and rolling to ensure it is being done on time Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on 7 00 AM 5 30 PM Ge heck amount of mats per cycle Note any empty zones heck shop order transactions performed on scheduled items note where they are at on the schedule Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule 7 30 AM 6 00 PM Check the number of times the equipment has been put in manual mode Check amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed heck build on mold Check overlap of edge strip Check bead placement Check carpet plac
44. n_downtime_date xls from share folder Step 5 Go to coulmn comments amp see the time Starting shift time and ending shift time Step 6 Calculate Run Time Ending shift time Starting shift time Step 7 Now go to template and to input tab Step 8 Based on the shop floor order xls file from kevan note down the carpet size Step 9 Go to input tab again enter the calculated Run time value in corresponding column for carpet size Step 10 Now go to EOS pdf file and navigate to a table with EOS as header Step 11 Note down the value near the row header open35 standards That value will be the total number of mats produced Step 12 Go to P and L template navigate to mats produced column Step 13 Enter the total number of mats produced in the corresponding date and corresponding type of mats produced Step 14 Go to the EOS pdf again navigate and find the Resource report header Step 15 Find note down the total value in row as Rubber and Carpet as header Step 16 Go back to P and L template go to materials column enter the total value of rubber abd carpet in the corresponding date column 2010 Millennium Infologic All rights reserved Millennium University Step 17 Go back to EOS pdf file navigate to the table with header miscelleneous resources and find the total values for each material Step 18 Go back to P and L template and go to expense column and enter the values in corresponding day s colum
45. nal comments gt gt Know the estimated run times for the current schedules and plan for pit stops Check for temperature of the dryer on each ch Check for no jet leaks or white lines 10 00 PM Check to see that the steamer temperature is set correctly 11 30 AM Verify correct penetration per schedule and monitor closely throughout the da Check for no bleeding on the carpet Did you find any other issues affecting productivity Record additional comments gt gt Check with trimmers for rejects and quality issues Know the estimated run times for the current schedules and plan for pit stops 12 00 PM Check amount of scrap coming off each Chromojet Check housekeeping and correct any issues immediately Did you find any other issues affecting productivity Record additional comments gt gt 2010 Millennium Infologic All rights reserved Millennium University 11 00 PM D id you find any other issues affecting productivity Record additional comments gt gt d Know the estimated run times for the current schedules and plan for pit stops Check that the size of the trimmed carpets are within specification Check for partial completed orders needing reprints GC Has the jet technician picked up bad jets e 11 30 PM C C GC heck amount of scrap coming off each Chromojet heck the investigate pallets for each Chromojet heck the temp of the steamer heck the temp of the dryer heck to see if stainguard is working i
46. ng to work instruction P5 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out P6 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the 4 00 PM P6 Check trimming operation Make sure the trimming is bein erformed to the work instructions P5 amp P6 Check perforating and mat rolling operation Ensure it is being performed according to work instructions P5 amp P6 Check logo matching and rolling to ensure it is being done on time P5 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the P6 Check wigwag and base sheet supply Ensure the correct sizes and compounds are staged so the P5 Check the amount of rubber on the edge strip robot Ensure roll has enough rubber and does not need 5 30 PM ji to be changed run out run out P5 Check amount of time it takes for the robot to wait for the rubber Must be 14 seconds or less for 3x10 land under 7 seconds for 85x150 euro Millennium University 5 Check computer rubber dimensions from extruder operator and ensure they are in spec 6 Check computer rubber dimensions from extruder operator and ensure they are in spec P5 P6 i i P5 Check amount of time it takes for onds or less for 3x10 and under 7 seconds for 85x150 euro P6 TEIST ress cycle on schedule 6 00 PM 5 Check mat removal Make sure cycle M
47. not 15 If the table is not empty Step 7 It shows an error in the process You have to export the table into a spreadsheet Step 8 Open the spreadsheet and make the alignment proper and make into a neat and presentable format Step 9 Add 2 columns after column routing They are Time passed from release date and Checking date in column L and column M respectively 2010 Millennium Infologic All rights reserved Millennium University i ate d 8 16409 Fannars 159742 0355 NHL Pitsbuigh Penguins Front 1 test ps bo SOUTHERN UNIVERSITY CARCARE 1 Jens cammara e GRAND VALLEY STATE FANMATS 65 0935 NVERSITY CARCARP 00841217 _ CARMAT3 3 ARIZONA STATE UNIVERSITY COL FOOTBALL 3 MASCOT MERCER UNIVERSITY COL STARTER 5 2 MASCOT hewa ERSITY COL STARTER 1 00845251 west ee boss ste UNIVERSITY COL STARTER E 00845235 a ee ou Le Lun mur Au 16 4ug 6 UNIVERSITY OF COL STARTER E 00641254 MASCOT 42655 Step 10 In column M put the current date i e the date when you check Step 11 In column L put a formula Checking date Order date column M column B Step 12 Drag the formula till bottom Step 13 Add 5 columns after column M They are 5 15 25 35 and Remarks in column N O P Q R respectively Step 14 Now minimize spreadsheet and open Macola Step 15 Open Macola MM gt Shop floor control gt View gt Shop order Status on screen Shop order status v
48. o Step 10 Press Tab until results get dispalyed Step 11 Press Enter on screen Shop order info Step 12 Click Operation button on screen Operation info Note In the window you can see certain results displayed which shows operation number 5 15 25 35 etc and the status of each operation started closed etc 2010 Millennium Infologic All rights reserved Millennium University Note If the planned qty is not equal to actual qty the transaction is Incomplete Step 13 Note down the operation numbers which are incomplete Step 14 Note down the Status and SFOrder number Step 15 Enter all the above details in corresponding columns Remarks column in the e Gen date xls Step 16 Repeat the same process from Step 2 to Step 15 for all Scheudle numbers in CJET A CJET B and CJET C Step 17 Do the steps for 2 shift as well 2010 Millennium Infologic All rights reserved Millennium University 2 2 Task Fanmats Managers Routine Part 1 Transaction Step 1 Log on to Citrix mil06 Step 2 Click on Transaction access file on screen Frm Transaction Table E frmTransactions Form 10 x REFRESH Name 35 not 25 25 not 35 Step 3 Ente Step 4 Refr 15 not 5 5 not 15 Released Note The pi Pie 15 not 25 Test EEE Step 5 Clicl on screen 15 not 5 Table Step 6 If the table shows empty that means there is no error and it shows desired output You can move on with 25
49. of the hot press UN Operator is using T square to cut mat in half at the exit of the hot press __ If operator does not use T square Lead must be notified DU Mat is being removed by folding in half as it comes off of the mold unless it is an edge corner mold stack of mats that are finished do not exceed 1 meter high cooling issues 2 30 PM 1 00 AM Mat specs are checked and called in it will range from 335 to 385 inches Blue fence has to be taken down D Have lead check for feed stops and the knife is at it s proper height PM to ie 30 AM to 3 30 PM 2 30 AM _ Ensure lead has completed end of shift documents se Ensure press partners have cleaned organized and the shift change is smooth 1st to 2nd transition Ensure the area was left clean and organized for end of day FT Ensure press partners have cleaned and gone on time Ensure all molds are emptied Za Ensure partners finish trimming remaining mats and finish rolling and stacking on pallets Ensure trim area is cleaned and organized o wegen and rollers have gone by 2 30 am 2010 Millennium Infologic All rights reserved Millennium University 2 4 Task Profit and Loss Part 1 For Big Press Step 1 Upon Receiving EOS pdf End of Shift file from Janice download the same from your mail box Step 2 Open the P and L template from W Shared MILControl Room PandLtemplate Step 3 Open the template to enter the values you got from
50. orders P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners 5 00 AM ing Make sure embosses are being changed for the day Make sure embosses are being changed for the day 5 30 AM o Ujo U Se Mog O 5195 ala 15 9 dch E Fla ol al 3 Ei a SL ol 8 3 3 Ol g o e vj 2 a o o 5 ol 81 ai x S cl Di o oj S nl 2 d cl 8 Qj ol D 5 2 D Ol O S 2 al o OI dg o 5 be bei gt 3 c oN og m 5 a a o 5 Q 5 D Q T T on m Wd bt ue Sg bt O E CH oO Q Di S O oO z a D Q oO a S S Sp bt D O gt 0 Q oO a D ag D a T T Glo 1 CO Siy 0 0 alo SIS s 5 cle 3 3 GI o o ole DD ale eler o o 315 ala 31 3 ele 515 2 13 515 G Z cl o Ota v 215 CG ze AE 315 Ua o 18 3 5 915 LAR OIF old HIH OO H ojo 213 0 0 ojo AA 313 sis 0 0 3 3 22 DD machine will not run out P5 Check amount of time it takes for the robot to wait for the rubber Must be 14 seconds or less for 3x10 and under 7 seconds for 85x150 euro P6 Check amount of time it takes for the robot to wait for the rubber Must be under 7 seconds P5
51. ort to the management staff The Control Room Team identifies variations of machine settings and assist maintenance in rapid troubleshooting of problems using Allen Bradley Logix 500 and Wonderware screens and cameras They also assist management on projects and reporting as requested 2010 Millennium Infologic All rights reserved Millennium University Table of Contents 1 Control Room Monitoring 1 1 What is Control Room Monitoring 1 2 Work Flow Diagram 2 User Manual Instructions 2 1 CJ Transaction and CJ Scheduling 2 2 Fanmats Routine Manager 2 3 Daily Check lists 2 4 Profit and Loss 3 Press Process Flow Diagram This User Manual is prepared based on the procedures followed till date These procedures are subjected to change according to the changes in the nature of task and when a new task is added or removed 2010 Millennium Infologic All rights reserved Millennium University CHAPTER 1 CONTROL ROOM 2010 Millennium Infologic All rights reserved Millennium University 1 1 What is Control Room Monitoring The Control Room operators monitor production operations on all equipment in the plant They identify machine slow down events and notify the appropriate supervisor or lead of the occurrence identify properly record events that cause slow down or down time identifies process and procedure variances and improvements properly record the variances and report to the management staff i
52. r the total number of mats produced in the corresponding date and corresponding type of mats produced Step 14 Go to the EOS pdf again navigate and find the Resource report header Step 15 Find note down the total value in row as Rubber and Carpet as header Step 16 Go back to P and L template go to materials column enter the total value of rubber abd carpet in the corresponding date column 2010 Millennium Infologic All rights reserved Millennium University Step 17 Go back to EOS pdf file navigate to the table with header miscelleneous resources and find the total values for each material Step 18 Go back to P and L template and go to expense column and enter the values in corresponding day s column Step 19 Go back to EOS pdf file and navigate to the table with header Total labor hours Step 20 Note down the total labor hours Step 21 Go back to P and L template and go to labor coulmn and enter the labor cost in the corresponding day s coulmn Step 22 Go to P and L tab in the P and L template Note There you could see total output of all entered values in the input tab Step 23 Now open a new spreadsheet and name it as daily target MMYY xls Step 24 Name a new tab as Press 2 4 MM for small press Step 25 Enter the current date in first column Step 26 Upon receiving square meter values from Simona note down SQM values and enter it in Mats produced column of P and L template under correspond
53. shop order transactions performed on scheduled items note where they are at on the schedule 5 Check computer rubber dimensions from extruder operator and ensure they are in spec 6 Check computer rubber dimensions from extruder operator and ensure they are in spec 6 Check amount of time it takes for the robot to wait for the rubber Must be under 7 seconds 9 00 PM 5 Check the number of times the equipment has been put in manual mode 6 Check the number of times the equipment has been put in manual mode 5 Check number of platens running Note any platens cancelled 6 Check number of platens running Note any platens cancelled 0 Uls Vis VI U U OUD OM On love OS O o 513 513 gt oe oles SIL 215 2 S 5 2 5 al SIS o 3 ole o ol5 elsa Oo w lo om B S 218 3 HI ol E 5 Oo o SI o bd n n SE o 5 2 n n a S D e Di ofl Si o ee amp a D Si s S Z o o CO el S F 8 D 8 8 m Ss 5 a 0 0 S amp 2 o v v a Ri n n 2 D 5 5 o al a Q Q 8 3 3 el ai o 5 be Cc 2 D gt s a a e ao ao pm pm 2 ol Oo 2 a 4 amp SN SN Qo e Q 3 D D ol ol o 8 S see al a be D a 10 00 AM OO 1 O a gt OD Q Lu gt OD 3 2 gt ra a a 35 gt OD oO Q Q OD n Si TD g a m 2 a oO g gt n 3 Q E
54. t and make alignment proper Step 49 Add a column Time passed from the release date Step 50 Put the formula Checking date Order Date and drag the same till bottom Note Save all the spreadsheets and email the reports DRAW PARETO CHARTS Refer Part 4 Part 2 Lazy Reports Step 51 Log on to Citrix Step 52 Go to Link FM To MM access file on screen Fanmats open order info breakdown Step 53 Hit Refresh Button Step 54 Click Fanmats Lazy Report 2010 Millennium Infologic All rights reserved Millennium University on screen Fanmats Lazy Report ES StartForm1 Form ll x FANMATS OPEN ORDER INFORMATION BREAKDOWN REFRESH DATA Ir WAIT WAIT for DONE pop up DONE WAIT for DONE pop up WAIT for DONE pop up Eorc Started Released Cancelled Shoporders Inv Shoporders Shoporders Shoporders Eorc R Shoporders Shoporders Find Insert Mats Open Orders Invoiced Open Picking Ticket No PO To With Tracking Shop Orders Not Invoiced Millennium Fanmat Lazy PO Not In Report Extend Millennium Check Orders Orders Step 55 Export the report to a spreadsheet and make the alignment proper Step 56 Add 2 columns Time passed from release date and Time passed from shipping date after the Quantity complete column Step 57 Add another 2 columns checking date and Remarks after 2 previously added columns Step 58 Go to column Time passed from release date and put the formula checking date Plac
55. t stainguard drum is full properly covered and fresh within 7 days heck that printer head speed is correct per carpet type customer heck that pump pressures are correct heck to see that there is adequate foaming in the steamer heck that the vacuum head is operational heck that stainguard nozzles are spraying correctly heck the stainguard sprayer will cycle correctly heck that brushes are in the correct position heck that dryer temperature is set correctl heck to see that the investigate pallets are empty erify number of people on the shift compared to master crewing guide id you find any other issues affecting productivity Record additional comments heck transactions from previous shift Are they complete now the estimated run times for the current schedules and plan for pit stops erify all planned schedules have a print utilization of at least 90 ach printer is to have a copy of the master scheduler plan for their printer for the shift heck that print schedules are being printed according to master scheduler heck that there is adequate carpet loaded to support planned schedules heck that wig wag carpet is positioned on cart evenly and contains correct placard heck that there is additional carpet available for the schedules for the day Q 5 00 AM lt 6 00 AM erify correct placard is posted for carpet that is being printed on oI lt Iololiololm lt AOO a CO lt ZA CO S EN EL Q V V o find any other iss
56. ter rubber dimensions from extruder operator and ensure they are in spec P6 gt nd under 7 seconds for 85x150 euro P6 ime i i press cycle on schedule 7 30 PM P6 Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the Ps i P6 e gt P5 ing i P6 ing S 5 Check mat removal Make sure mats are being removed without delay of the next cycle Make sure Millennium University P5 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners P6 Check build on mold Check overlap of edge strip Check carpet placement by robot Look for any adjustment by QA partners 8 00 PM P5 Check trimming operation Make sure the trimming is being performed to the work instructions P6 Check trimming operation Make sure the trimming is being performed to the work instructions 9 30 AM P5 amp P6 Check perforating and mat rolling operation Ensure it is being performed according to work instructions 5 amp P6 Check logo matching and rolling to ensure it is being done on time 5 Check coverage in all positions due to break time on the lines 6 Check coverage in all positions due to break time on the lines 8 30 PM to be changed to be changed run out run out 5 Check shop order transactions performed on scheduled items note where they are at on the schedule 6 Check
57. to warm up molds Time of cycles should be 10 minutes 600 seconds Temperature should be 330 F Pressure should be off 0 P6 Check if operator is cycling empty molds through press to warm up molds Time of cycles should be 10 minutes 600 seconds Temperature should be 330 F Pressure should be off 0 P5 Extruder operator starts extruding rubber Speed of extruder should be from 1125 1275 for 3 x 10 land 620 720 for 85 cm x 150 cm euro Write speed in comment section P6 Extruder operator starts extruding rubber Speed of extruder should be from xx for 4x6 or 115x180 cm and yy for 3x5 or 85x150 cm Write speed in comment section U Eu Q E ei gt fo 3 D el 3 o a D D a 5 Q d c D ae 2 E Ku a o 3 2 3 E 3 Q 9 a TI UU olulo 1 COOC 51510 o l is ZC alo 01012 313 D T 3 SIS Im zl sys SAS See a deis 223 3 3 22 AE 8100 10 s alo lS p l a olo lo 3 3 ole EES S cl c a 0100 sjo lolo elef 0101313 SIRIEI ae ole 51513 010 lo olo 51519 oino CIC o o ler bal ba 0 Ke k lt aye o o 515 on tell te o o O 10 QO ba 0 ie x cE gt oO D 3 fe E el E D ex al kel 5 gt a a Q Q oO a Ki D g m D S oO x a bai D Ki al 3 E Q a Si E D ex al D 3 bei Q a Ki 3 a a a to be changed 3 30 PM i
58. ues affecting productivity Record additional comments heck to see that all colors are assigned correctly onfirm that all loaded colors have not reached expiration onfirm that all loaded colors have been stirred prior to use erify that all colors needed have been checked for correct viscosit onfirm that pH is recorded on the drum labels and is within spec erify timing of next schedule change and ensure pit crew is ready 6 30 AM heck to see if stainguard is working if needed heck for any extra jets or tips laying around heck c j a to ensure the bank of extra pumps is loaded for the next schedule change heck for no jet leaks or white lines erify steamer temperature is set correctl erify correct penetration per schedule and monitor throughout the da heck for no bleeding on the carpet id you find any other issues affecting productivity Record additional comments Check with trimmers for rejects and quality issues Know the estimated run times for the current schedules and plan for pit stops Check amount of scrap coming off each Chromojet 7 00 AM Check housekeeping and correct any issues immediately heck filters Note how many were changed and which pumps have been changed Check jets Note how many were changed and which jets have been changed Did you find any other issues affecting productivity Record additional comments Verify each printer is using master schedule page to mark through acceptable printed items Know the estimated run times for the current
59. umn and enter the values in corresponding day s column Step 19 Go back to EOS pdf file and navigate to the table with header Total labor hours Step 20 Note down the total labor hours Step 21 Go back to P and L template and go to labor coulmn and enter the labor cost in the corresponding day s coulmn Step 22 Go to P and L tab in the P and L template Note There you could see total output of all entered values in the input tab Step 23 Now open a new spreadsheet and name it as daily target MMYY xls Step 24 Name tab as Press 5 6 MM for big press Step 25 Enter the current date in first column Step 26 Goto production downtime xls amp get values of total cycles see commentbox Step 27 Enter that value as second column in press 5 6 tab of daily target MMYY xls Step 28 Enter the Total labor cost from P and L template and enter it as 3 column of press 5 6 tab of daily target MMYY xls Step 29 Get the Downtime value from production downtime xls Step 30 Enter the Downtime values as 4 column of press 5 6 tab of daily target MMYY xls Step 31 Get the Extra material cost value from P and L template input tab Step 32 Now enter extra material cost value in 5 column of press 5 6 tab of daily target MMYY xls Step 33 Now go to EOS pdf and go to table with header EOS report and get the scrap and reworks value Step 34 Enter those values as 6 column of press 5 6 tab of daily target MMYY xls Step
60. unloader loader time Is the press cycle on Check amount of mats per cycle Note any empty zones heck build on mold Check overlap of edge strip Check bead placement Check carpet placement 11 00 AM Size and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on heck amount of mats per cycle Note any empty zones Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule 41 30 AM 10 00 PM heck the number of times the equipment has been put in manual mode Check amount of mats per cycle Note any empty zones Check mat removal Make sure mats are being removed without delay of the next cycle Make sure mats are being brushed properly if needed 2010 Millennium Infologic All rights reserved 12 00 PM 12 30 PM 1 00 PM 1 30 PM 2 00 PM 2 30 PM 3 00 pm to 3 30 PM 10 30 PM 11 00 PM 11 30 PM 12 00 AM 12 30 AM 1 00 AM Millennium University Check build on mold Check overlap of edge strip Check bead placement Check carpet placement Check wonderware and note any delay in cycle times Use trend or watch unloader loader time Is the press cycle on schedule heck amount of mats per cycle Note any empty zones heck base sheet supply Ensure the correct sizes and compounds are staged so the machine will not run out heck edge strip supply Ensure the correct sizes and compounds are staged so the ma

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