705 Rebuild Team Outpaces Schedule

(June 2006) When Andersen’s order file for their Frenchwood® door stiles and rails didn’t thin out like it normally does in December, Plant 7’s leadership and millwrights started to worry. They had already run the 705 cold clamp 13 months without a rebuild, and they knew they were going to have to shut the line down for nine days to replace worn parts.

Or did they? After a challenge to halve the time from CEO/President Dallas Stovall, project planners put their heads together and narrowed the window to five days. The 31-person team who worked night and day to rebuild the 705 did the plan one better by finishing two shifts before schedule – a difference of eight truckloads of outbound product for the busy 705 line.

“The 705 cold clamp has more than 6,800 separate parts and many of them are moving parts that must work together to produce the desired results,” Doug Marcoe, South End Maintenance coordinator, said. “It is comprised of 46 clamping stations and 12 individual clamps at each station.”

During a rebuild, it takes nine people to remove each clamping station. The clamps are steam cleaned before another two- or three-person team inspects each one and replaces any worn parts. The necessary repairs take between one to four hours on each of the 46 clamping stations. Another 11 people are needed to reinstall the clamping stations back in to the frame. And, while all this is going on, other teams are repairing the carousel drive system, mainframe, lubrication system, and tightener battery.

“Timing and teamwork were critical for success,” Doug said. The 705 crew and other production folks worked hand in hand with millwrights from Madras, Redmond, and Bend. Planners kept the work flowing by renting two steam cleaners (instead of one as in past rebuilds) and reconfiguring the rebuilding stations to ease the delivery and removal of clamping stations. They outfitted each station with all the tools needed to do the job. They staffed the critical disassembly and assembly steps with 705 rebuild veterans and gave them air tools to further speed up the process.

Doug said a Failure Mode Effects Analysis (FEMA) from a few years back also contributed to the rebuild’s quickened pace. “Many improvements were made to the entire 705 system during the FEMA,” Doug said. “Some increased longevity of parts, while others made it easier to work on and replace parts.”

“The 705 rebuild is a great example of what Bright Wood can do when we put our heads down, develop a good plan, and then execute that plan,” Lance Goicoa, Madras Lamination Value Stream manager, said. “My hat is off to all those involved. You beat the plan by two shifts while working 12-hour blocks through a weekend. My thanks also to the plants and departments who covered for the folks involved in the rebuild. We all worked together and it is very much appreciated.”

Other Newsletter Articles:

Madras Door Frame Plant Nails All Box Score Targets in March (June 2006)

Take the Steering Wheel with Diabetes (June 2006)

2P + 2 Products + 2 Crew Members =
2 Percentage Points to Run Time Goal (March 2006)

Consolidation Idea Rejuvenates Skid Row (March 2006)

In-Plant Mill Supplies Keep Drivers Home (March 2006)

Bright People Donate $11,742 to Central Oregon Charities in December (March 2006)

Bright Wood to Close Bend Facility (Company announcement released February 17, 2006)

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