Title: Lean Manufacturing 2
1Lean
Manufacturing
Visual Systems
2Lean Building Blocks
Continuous Improvement
Pull/Kanban
Quick Changeover
Quality at Source
Cellular/Flow
Batch Reduction
Plant Layout
TPM
Standardized Work
5S System
Visual Systems
POUS
Value Stream Mapping
Teams/Employee Involvement
Source The MEP Lean Network
3Visual Factory
- Ability to understand the status of a production
area in 5 minutes or less by simple observation
without use of computers or speaking to anyone.
45S
Method for creating and maintaining an
organized and clean workplace.
5(No Transcript)
61S - Sort - Seri
Separate and Discard
71S - Sort - Seri
- Identify all necessary and unnecessary items.
- Move unnecessary items from workplace to a
designated area or throw it out. - Remove all excess items from working areas work
pieces, personal items etc. - Organize all remaining necessary items.
- Designate a team to hunt down unnecessary
items.
82S - Stabilize - Seiton
Set in Order Straighten Arrange and identify
for ease of use
92S - Stabilize - Seiton
- Locate materials and tools at POINT- OF- USE
(POUS). - Store items needed by most people in a common
storage area. - Make items easily identifiable and easy to
obtain. - Label all containers, totes, supplies etc.
- Storage areas, work areas, containers should have
floor marking and identifying labels. - Place Maintenance/Operator instructions close to
the point of use. - Use special device (carts/shelves/racks) to
organize tools and fixtures. - Performance boards daily/weekly production,
scrap/rework rate chart.
102S Visual Controls
- Label Containers, Cabinets, Supplies,
Inventory, Machines, Tools, Scrap, Rework,.. - Color Parts container, floor markings,
safety, work areas, trash cans,.. - Green Shipping, Yellow Work in process, Blue
Storage/Trash. - Checkered Aisles.
- Footprints Anything that is movable.
- Tool Boards Shadow board, Peg board.
- Performance Boards Hour by hour, 5S
Measurement, - Standard Work visible.
- Re-order points, Inventory levels.
- Material Flow indicators within, into, out of
your cell. - Equipment related information.
- Documents on safety, quality,
113S - Shine - Seiso
Clean up Scrub
123S - Shine - Seiso
- Use dust collecting devices to prevent possible
dirt. - Ensure that electrical and other cords are not a
hindrance to all personnel. - Operators should clean their work area and
equipment and perform preventive maintenance. - Keep everything clean for constant state of
readiness.
A Clean Workplace enhances QUALITY, SAFETY, and
PRIDE.
134S - Standardize - Seiketsu
Keep Clean
144S - Standardize - Seiketsu
- Implement a plan to keep the workplace clean all
the time - No unnecessary items, mess, dirt
- Who?
- When?
- How?
155S Schedule
165S - Sustain - Shitsuke
Motivate
175S - Sustain - Shitsuke
- Commitment
- Adherence
- Cell meets 5S principles at the end of each shift
- 5S Daily Checklist
185 Minute 5S
Five Minute 5S Five Minute 5S Five Minute 5S
Area Area Contact
Sort Remove unwanted tooling (red tag to holding area) Remove unwanted tooling (red tag to holding area)
Set Mark out product variants (floor tape from Joe) Mark out product variants (floor tape from Joe)
Shine Degrease banjo press (gloves, solvent from Joe) Degrease banjo press (gloves, solvent from Joe)
Standardise Why is banjo press greasy, Why are variants mixed Why is banjo press greasy, Why are variants mixed
Sustain Who is/are responsible for press Who is/are responsible for press