productivity improvement thru' lean tools

8/7/2019 Productivity improvement thru' Lean Tools

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Productivity Improvement Program thru’Lean Manufacturing

Agenda for Lean Manufacturing Program

1) Program Synopsis2) Objective3) Preparing for the event 4) Kaizen Methodology 5) Detailed event sequence6) Follow up7) Evaluate

1) Program Synopsis : -

Kaizen event is a 2 ~ 5 day focused improvement activity during which a sequestered,CROSS-FUNCTIONAL TEAM designs and fully implements improvements to a defined

process or work area, generating rapid results and learned behavior.

So, a Kaizen eventi) Is a highly focused “assault” on an area or process to achieve rapid improvement

ii) Uses a cross-functional team with process insiders and outsiders

iii) Achieves as many improvements as possible during a typical 3-5 day event

iv) Augments, but does not replace, continuous improvement.

2) Objective :-

Kaizen event comes with an objective to

i) Aligning cycle time with tact timeii) Waste eliminationiii) Employing pull system at productioniv) Improving productivity by at least 30%

3) Preparing for the event : -

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_________________________________________________ KAIZEN Breakthrough

Event _______

Key ingredient of a kaizen event is a dedicated CFT (Cross Functional team), which isalways heading towards the premium goal of the event thru’ brainstorming and otherdifferent LEAN tools.

i) Selecting Team Sponsor

(1) High level champion of the cause

(2) Upper management advisor to the team

(3) Breaks through road blocks

(4) Arranges support for the team during the event

(5) Ensures coverage so that team members are not interrupted during the event

ii) Selecting Team Leader

(1) Determines session objectives and process to be followed(2) Meets with facilitator to review session objectives and process

(3) Sends agenda to team members in advance(4) Is the leader, not the boss(5) Has experienced a kaizen event(6) Good knowledge of lean manufacturing (if production area event)(7) Good knowledge of waste elimination techniques

iii) Choosing Facilitator

(1) Manages how people work together during team activities(2) Keeps activities moving along the process and time schedule set by the team

leader

iv) Choosing Team Participants

(1) Insiders – who work in or around the process(a) Machine Operator(b) Supervisor

(2) Outsiders – who can provide non tainted view points & new Ideas(3) Recorder – Usually a team member who

(a) Records important results, actions, & decisions(b) Promptly distributes minutes to participants

v) Develop the Team Charter

vi) Gathering data prior to the event

(1) Process steps(2) WIP levels(3) Capacities/process times(4) What is produced and how much?(5) Cycle and queue times(6) Batch sizes & changeover frequency(7) Defect Rates(8)Up-time

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Event _______ (9) Number of operatorsPhotos and layout of the targeted area

vii)Prepare the organization

Developing a sense of trust across the organization

Generating enthusiasm about the event Demonstration of commitment by management

Publicizing the event - before and after

Getting the union to cooperate

• Team Kickoff (includes sponsors)

Review draft charter, modify, approve

Develop code of conduct (agreement on rules)

Discuss training and event logistics, etc.

4) Methodology :-

PlanDay 1 Find & analyze current state & perform

Root Cause AnalysisDay 2 Design future state

Do Day 3Design & test improvements using LEAN

tools

Check Day 4 Obtain confirmation of applications

Check &Action

Day 5Finalize improvements, make new SOPs,

Train process workers, do close outbriefings

5) Detailed KAIZEN event sequence :-

Ten steps from start to finish

i)Training and kick-off activities(a) Lean Manufacturing (if in production area)

(b) Tools of continuous improvement (Pareto, Fishbone, Run charts, 5-whys,Process analysis)

ii) Making and analysis of “CURRENT STATE”iii) Select Area of focusiv) Create area of solutions

v) Select solutionvi) Plan & implementvii) Train operators

viii) Standardize and sustain new SOPsix) Follow up & Evaluatex) Celebrate

6) Follow-up

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Event _______ This phase of the Kaizen process involves the completion of the Improvement andControl DMAIC elements. The success of the Kaizen depends on timely completion of theImprovement process and effective change management. This process involves:

Following-up to ensure that action items are successfully completed

Working with Lean Champions to breakdown obstacles

Measuring the actual results of the Kaizen to document and quantify benefits

Establishing process control to ensure the ability to consistently obtain improved performance

7) Evaluate

This is the last phase of the Kaizen process cycle. A Lean enterprise is a learningorganization that recognizes Kaizen as a continuous process of improvement through:

Identifying improvements to the Kaizen implementation process

Encouraging employees to identify further improvement opportunities

Establishing a schedule to re-evaluate the VSM and start a new Kaizen improvement cycle

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productivity improvement thru' lean tools

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