Improving Efficiency of Production ProceduresTsz Fok spent a large part of his gap year working on a valuable efficiency study of the 'Finalising Procedure' at Turner Powertrain Systems. He undertook an in-depth evaluation of the final stages of the production of transmissions involving the Test Rigs, Wash and Paint System and Final Assessment. He was also responsible for re-writing the existing test programme to improve efficiency and reliability. Following his four-month investigation, Tsz produced a new procedure and a new test programme that will save the company £78,000 p.a.
Background:
Turner Powertrain Systems, a subsidiary of Caterpillar Inc is a global leader in providing power control solutions and supplies CAT facilities and other customers with transmissions and transmission components. While at Turner Powertrain Systems, Tsz was asked to carry out a '6-Sigma' project with the aim of reducing waste in resources and manpower in the Finalising Procedure. Initially he was set the target of cutting at least 1,500 man-hours of production time by eliminating some of the non-value-added processes from the procedure.
Approach:
Employing the Lean 6-Sigma Methodology, Tsz first had to quantify the waste. He used the industrially recognized MTM-X System (Methods Time Measurement) to accurately analyse each operator's activity, and successfully identified several bottlenecks within the procedure. Tsz used statistical calculations based on three months of data to show that the cycle time of the transmission could be heavily reduced. Tsz suggested combining parts of the process to cut down the queuing time and designed a mechanism to be fitted in on the track, which would automate some other elements of the procedure.
Results:
Tsz produced an extensive report on his findings along with a list of recommendations. By combining certain processes 3,000 man-hours will be saved p.a.- approximately equivalent to saving £50,000 p.a. Moreover it will also halve the time a transmission spends in the system making the process significantly more efficient. Some of Tsz's recommendations have already been utilised by Turner Powertrain and following his report the company has also begun building an extension at the end of the track to smooth the transition onto the next stage of production.
"The range of his activities in this project, from statistical analysis to operator involvement, was extensive, and with his combination of high intellect, interpersonal skills, and persistence, Tsz has succeeded in all aspects."
Mr Robert T. Smith, Human Resources Manager
An Appreciation
Tsz Fok who has been killed in a bicycle accident in Oxford at the age of 22 was an outstanding student of engineering, a gifted musician, but above all else an engaging and personable young man. To say that Tsz was likeable is to understate the affection and high regard of all who met him, but it does convey something of the immediate quality of his friendship and his amiable manner with people.
Tsz was born and educated in Hong Kong until at the age of 12 he came to the UK and continued his education at Solihull School. His academic prowess was recognised early and his record of 8 Grade A GCSE A2 Levels clearly marked him as an outstanding student of his year. His passion for music was similarly reflected in high achievement with Grade 8 distinctions in piano and wind instruments.
A natural progression to Oxbridge and a mathematics first seemed certain, but Tsz took up the option of a Year in Industry, working for Turner Powertrain. in Wolverhampton. The year in the engineering industry proved revelatory and prompted Tsz to a deeper understanding of the role of engineering in solving some of the problems and challenges of the future. Whilst with the company, Tsz recommended changes to the production process, saving over £75,000 per year.
Tsz took up his place at Worcester College Oxford in 2004 to study Engineering, Economics and Management. A year later he was nominated to NESTA, the National Endowment for Science, Technology and the Arts, for an award under the Ignite! Creative Sparks programme. In arriving at the subject for his supported project, Tsz reflected on his own experience and journey towards engineering, and set about raising the profile of STEM subjects (science, technology, engineering and maths) as creative, exciting, challenging and important for more young people to follow as courses of study and as careers.
The booklet that Tsz wrote, and which was published just 5 weeks before he died, Shape the Future, comprises interviews and profiles of 20 leading figures in the worlds of science and engineering, including Sir James Dyson, Lord Sainsbury, Carol Vorderman and Emily Cummins. Tsz's ambition was to present to young people a series of role models they could emulate and follow; in truth, of course, the best role model for young people was Tsz himself, though he would be too modest to say so.
At Oxford his achievements reflected his wide range of interests, enthusiasm and energy; he played oboe in the University Orchestra, was Secretary of the JCR, Captain of coxes for the rowing club, and excelled at badminton and ballroom dancing.
As he said in a Guardian interview in November 2003, 'This period of my life is the most productive, mentally and physically. Both my parents went to university late and they've told me that, after a certain age, you start to think slower. If I can absorb as much knowledge and experience as I can now, it'll stand me in good stead later.'
And in an interview for New Scientist in June 2005, Tsz explained how to keep a balance at University between the demanding courses of engineering and a decent social life - 'I've never had a day when I've got nothing to do'.
Additional note:
Everyone at The Year in industry is deeply saddened by the death of Tsz Fok; and send deepest condolences to Tsz's family and friends in Birmingham, and Hong Kong.
April 2007
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