1. Nortel Indoor Legacy – Poka-Yoke ( Assembly) Kaizen Jul 2007 Lean Campus Programm

2. 2 Phase 1 – Planning and Preparation Schedule

3. 3 Focused Improvement Team Data Analysis Objective: Implement Poka Yoke to avoid Quality issues and increase productivity by reducing grinding operations Issue: Legacy frames suffering deformation from regular welding heating. Concern/problem: Production must re-work frames after welding stage. 5 4 3 2 1 WHY? Solution Build a Fixture to hold frame to avoid deformation (ARM HOLDER FIXTURE). Build a Check Rule to get the critical dimension assured from welding starting point. After soldering hold fixtures into body frame until they reach room temperature. Eliminate hammer striking. Reduce grinding. Frames are out of Spec’s in width (1/4”-3/8”) There is no Fixture to hold frame while welding Frames are suffering contraction from heating. Phase 2 – Objective, Why Analysis & Solution

4. 4 Phase 2 – Results reviewing

5. 5 Phase 2 – Show and Tell (BEFORE) WIP WIP in queue and waiting for REWORK causing long lead time. REWORK takes 25 min Average. Dimension need RE-INSPECTION. Frames need to be GRINDED to eliminate burrs and waves on surface taking 20 min. Average.

6. 6 Phase 2 – Show and Tell (AFTER)

7. 7 Phase 3 – Lessons learned, - Simple but smart ideas can contribute to improve substantially a complex process like welding assembly. - Team will combine kaizens with other improvement initiatives to enhance and produce better results. - People is being well motivated by the results observed and are committed to continuously work as team. - Safety in welding department is key before they observe any improve.

8. 8 Phase 3 – Next Steps! THANKS - Integrate this kaizen with a major kaizen event to take advantage of this new way to make processes more productive. - Although training is in place, they are forming a taskforce to develop and share skills and experience to train others in the new processes. - Gap analysis chart will be displayed in place to asses, enhance and track lean achievements. Focus: Training Involvement