Y-12 Respirator Flow Cycle Time Reduction Project

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Description

In mid-July 2000, a Cycle Time Reduction (CTR) project was initiated by senior management to improve the flow and overall efficiency of the respirator distribution process at Y-12. A cross-functional team was formed to evaluate the current process and to propose necessary changes for improvement. Specifically, the team was challenged to make improvements that would eliminate production work stoppages due to the unavailability of respirators in Y-12 Stores. Prior to the team initiation, plant back orders for a specific model respirator were averaging above 600 and have been as high as 750+. The Cycle Time Reduction team segmented the respirator ... continued below

Physical Description

22 pages

Creation Information

Hawk, C.T. & Rogers, P.E. December 1, 2000.

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This report is part of the collection entitled: Office of Scientific & Technical Information Technical Reports and was provided by UNT Libraries Government Documents Department to Digital Library, a digital repository hosted by the UNT Libraries. More information about this report can be viewed below.

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  • Oak Ridge Y-12 Plant
    Publisher Info: Oak Ridge Y-12 Plant, TN (United States)
    Place of Publication: Tennessee

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Description

In mid-July 2000, a Cycle Time Reduction (CTR) project was initiated by senior management to improve the flow and overall efficiency of the respirator distribution process at Y-12. A cross-functional team was formed to evaluate the current process and to propose necessary changes for improvement. Specifically, the team was challenged to make improvements that would eliminate production work stoppages due to the unavailability of respirators in Y-12 Stores. Prior to the team initiation, plant back orders for a specific model respirator were averaging above 600 and have been as high as 750+. The Cycle Time Reduction team segmented the respirator flow into detailed steps, with the focus and emphasis primarily being on the movement of dirty respirators out of work areas, transportation to Oak Ridge National Laboratory (ORNL) Laundry, and return back to Y-12 Stores inventory. The team selected a popular model respirator, size large, to track improvements. Despite a 30 percent increase in respirator usage for the same period of time in the previous year, the team has reduced the back orders by 89% with a steady trend downward. Summary of accomplishments: A 47 percent reduction in the average cycle time for dirty respirators to be laundered and stocked for reuse at the Y-12 Complex; A 73 percent reduction in the average cycle time for dirty respirators to be laundered and stocked for reuse specifically for major users: Enriched Uranium Operations (EUO) and Facilities Maintenance Organization (FMO); Development of a performance measure for tracking back orders; An 89 percent reduction in the number of laundered respirators on back order; Implementation of a tracking method to account for respirator loss; Achievement of an annual cost savings/avoidance of $800K with a one-time cost of $20K; Implementation of a routine pick-up schedule for EUO (major user of respirators); Elimination of activities no longer determined to be needed; Elimination of routine complaint calls to Stores requesting respirators; and Recommendation of improvements at the supplier (ORNL Laundry and Quality groups).

Physical Description

22 pages

Source

  • Other Information: PBD: 1 Dec 2000

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Identifier

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  • Report No.: Y/DN-407
  • Grant Number: AC05-00OR22800
  • DOI: 10.2172/774311 | External Link
  • Office of Scientific & Technical Information Report Number: 774311
  • Archival Resource Key: ark:/67531/metadc719596

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Creation Date

  • December 1, 2000

Added to The UNT Digital Library

  • Sept. 29, 2015, 5:31 a.m.

Description Last Updated

  • May 6, 2016, 2:12 p.m.

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Citations, Rights, Re-Use

Hawk, C.T. & Rogers, P.E. Y-12 Respirator Flow Cycle Time Reduction Project, report, December 1, 2000; Tennessee. (digital.library.unt.edu/ark:/67531/metadc719596/: accessed August 21, 2017), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.