Engagement Result
Major Command: Air Force Materiel Command (AFMC) - U.S. Air Force
Organization: Ogden Air Logistics Center (OO-ALC)
Group: 309th Commodities Maintenance Group (309 CMXG)
Project: Re-Engineer Chrome Plating Process & Implement a Sustainable TPM Program
Assignment:
An internal assessment of the 309 CMXG's chrome plating process revealed that the current state Value Stream Map (VSM) contained 14 grind / plate / grind rework loops. These re-work loops were conservatively estimated to cost $5 million per year. MainStream GS was engaged to re-engineer the 309 CMXG's chrome plating process and implement a sustainable Total Productive Maintenance (TPM) program.
Actions:
MainStream GS assembled a small team of platers, grinders, wage leaders, and first line supervisors to collect data. Data collected revealed that pitting of the chrome plating was by far the major defect type. Over the period of a year, pitting defects grew from 6% to 13% of parts going through chrome plating. MainStream GS implemented a preventative maintenance program, which included replacing plating baths with fresh solution on a set schedule and conducting regular tune-up and upgrades to the rectifier system. In addition, the chrome plating training program was overhauled to be more comprehensive and focused on training platers in low resistance set-up techniques.
Results:
Resulting included reducing:
- Pitting defects by 75%
- Grind / plate / grind rework loops by 79%
*Savings as a direct result of this project were estimated at $3.5 million annually