Operations InternBedford Heights

Brian Drellishak

• The Ohio State University• Operations Management Major– EEDS Minor (Environment, Economy,

Development, Sustainability)• Graduate in May of 2018• Supervised by:– Mark Baker– Melinda Rutledge– Corey Cheek

Background Information

• Reformat and Update Plant SOPs (Packaging and Fillroom)– Goal: Create a updated document that showed how to operate a machine

following standardized steps.– Take old format SOPs and convert them to the new standardized format.– Spent time at each machine (2-5 days depending on the machine) observing,

asking questions, taking notes, and updating the information on the SOPs.– Spent time on floor observing how the machines interact with other machines,

how the operators interact with the machines, and how the operators interact with other operators.

– Practice Gemba, “the real place,” the idea that the best improvement ideas will come from spending time on the floor where value is created and gaining an understanding of the true pulse of the factory floor.

– Formed relationships with operators and supervisors.– Understand the production schedule.– Observe machine failures and problem solving methods by operators,

maintenance, and production supervisors.– Helped operators with quality control on the line

• Eg: Notice mislabeled cans, remove mislabeled cans from the line, clean/take the label off, put it back before the labeler, etc.

Key Projects

• Kaizen Training Event– A quick, highly structured and coached intense attack on waste in a process

or work area by a small team– Focused on the Depalletizer and can waste– Split into small teams in order to tackle small improvements that we decided

as a group were feasible and had a good chance of having an impact. • Worked with Matt Conover (Sr. Ops Manager, Continuous Improvement) to

determine where most of the can waste was coming from, the amount of the can waste that was “good” (still usable), and determine a rough monetary cost to recycling these “good” cans.

– Saw the effects of what we did during the event• Replaced perfect yield light on top of can counter, installed new pallet guides for

pallet conveyor, updating SOP to include taking cans off of middle of each layer to clamps don’t knock them off

• Available and flexible to do other tasks needed by managers– Eg: Inventory, list of responsibilities for operators, etc.

Key Projects

• How did you apply what you learned in class to your internship?– Word and Excel skills– Self-direction and motivation– Organization– Asking good questions– Planning and deadlines– Knowledge and experience gathered in Bedford Heights will be

valuable for my major classes, career, and beyond– Kaizen was an educational experience that will give me a head start

when I start taking my major core classes. We learned about:• The Kaizen Cycle• The 8 different types of waste and how to identify them• SMED• FMEA• Gemba walk

Educational Relevance

• Explain the value of your project(s) to you – New experience in a plant environment with the

entire line.– Form professional relationships and act

professionally– Learn about the relationships between managers

and employees and what makes that relationship effective

– Learn about the structure of the company, Global supply Chain, and the Standard Work matrix

Educational Relevance

• Explain the value of your project(s) to the company– Creates a standard which results in clear

expectations and responsibility on the part of the operator.

– Adherence to reliable method which maximizes performance, reduces variation, and ensures safety.

– Facilitates training.– Encourages regular evaluation of work activity and

continuous improvement.

Educational Relevance

“Where there is no standard, there can be no improvement.” -Taiichi Ohno, Inventor of the Toyota Production System

• What would you do differently if given another opportunity?– Ask more questions at the beginning.– Planned out my work flow better.

• Wasn’t able to complete Line 6 Electromatic Filler – More efficient way of making changes to SOPs.

• Bringing out laptop to the packaging line to make changes VS printing out a copy of newest version of SOP, making notes, bringing it up to laptop to make changes, repeat

– Ask about SOP Level 1 Pillar piece sooner to have the possibility of getting it.

– What do you think I could have done differently?

Educational Relevance

• THE PEOPLE• Friday lunches

Highlights from Internship

• Giving me this opportunity and experience

• Questions, comments?

THANK YOU!