Agenda Welcome and Introductions MLC Overview Introduction to Lean - PowerPoint PPT Presentation

Agenda ❖ Welcome and Introductions ❖ MLC Overview ❖ Introduction to Lean ❖ The 8 Wastes ❖ Personal Kanbans ❖ Standard Work Exercise ❖ Error Proofing ❖ 5S ❖ Kaizen ❖ Sustaining and Maintaining the Concepts ❖ What will you do Monday? 62

Error Proofing Sorting and Inspection Co. ❖ Our company goal is to find all the letter “F’s” for our clients ❖ We get paid by the F, so its imperative that we find them all ❖ Work is piling up, so work through your task as fast as you feel comfortable ❖ OK, go to work! 63

Error Proofing How many got more than 25? More than 30? More than 35? More than 40? 45? 46? 47?……… 64

Error Proofing 65

Error Proofing In 100% inspection there is an 80% chance of finding the problem (if it exists). If two people inspect the item, the chance of finding the problem drops even further! Why? Inspector 1 thinks inspector 2 will catch the defect while inspector 2 thinks inspector 1 will catch it. Net result: nobody inspecting. - From Juran / Deming 66

Error Proofing Levels Instruction / Tell Inspect for defects “after the fact” Visual management and signs Make it difficult for humans to do it wrong Automatic shut down if error occurs Physically impossible to make a mistake Which are detection, which are prevention? 67

Agenda ❖ Welcome and Introductions ❖ MLC Overview ❖ Introduction to Lean ❖ The 8 Wastes ❖ Personal Kanbans ❖ Standard Work Exercise ❖ Error Proofing ❖ 5S ❖ Kaizen ❖ Sustaining and Maintaining the Concepts ❖ What will you do Monday? 73

5S ❖ THE NUMBERS GAME ❖ Pretend that you have 36 items that you use every day in your work area. ❖ In 15 seconds find all of the numbers from 1 – 36 -- IN ORDER .

78

5S Sort “What can we get rid of?” “Where does it go?” “What needs to be fixed?” “How do we fix it?” “When in doubt, move it out!” 79

5S ❖ How many items do we use each day? ❖ Try again? ❖ In 15 seconds find all of the numbers from 1 – 36 -- IN ORDER . 80

82

5S Straighten/Store “The basic point of workplace organization is to fix/set the layout of tools or equipment so that everything is readily available when it is needed .” 83

5S Straighten/Store 84

5S Straighten/Store ❖ Organize everything that remains; make locations visible and self-explanatory ❖ Designate storage locations 85

5S Straighten/Store “A place for everything and everything in it’s place” 86

5S Straighten/Store ❖ VISUAL MANAGEMENT is key (see next section ) ❖ Labeling ❖ Signage ❖ Floor markings, etc . 87

5S Straighten/Store 1 2 3 4 5 6 7 8 9 10 Audio and Visual Controls 88

5S Straighten/Store 89

5S Straighten/Store 3/4” 1/2” 7/8” 90

5S Straighten/Store BEFORE AFTER • Bubble wrap roll on floor – Have to bend and • Installed dispenser for easy access and reach twist constantly to reach roll. • Improved ergonomics – no more bending and • Unnecessary motion – Extra steps to reach roll twisting • Safe work area • Unsafe condition – Trip hazard

5S Straighten/Store Identifying the Need for 5S and Waste Reduction • Do we need 5S? Can you identify any “waste”? 92

5S Straighten/Store Before After 93

5S Straighten/Store Before After Create a Place for Everything, and Everything in Its Place 94

5S ❖ Try again? ❖ In 15 seconds find all of the numbers from 1 – 36 -- IN ORDER . 95

• Still, What’s Missing? 97

5S ❖ Try again? ❖ In 15 seconds find all of the numbers from 1 – 36 -- IN ORDER . 101

103

• How much time can you save or what can you learn about your organization with these principles? 104

5S How often you do the task: 50 Times per 5 Times per 1 Time per 1 Time per 1 Time per 1 Time per day day day week month year 1 Second 3 Hrs/Yr 21 Min/Yr 4 Min/Yr 1 Min/Yr 0 Min/Yr 0 Min/Yr 5 Seconds 17 Hrs/Yr 2 Hrs/Yr 21 Min/Yr 4 Min/Yr 1 Min/Yr 0 Min/Yr How much time you shave 30 Seconds 2 Wks/Yr 10 Hrs/Yr 2 Hrs/Yr 25 Min/Yr 6 Min/Yr 1 Min/Yr 1 Minutes 3 Wks/Yr 21 Hrs/Yr 4 Hrs/Yr 50 Min/Yr 12 Min/Yr 1 Min/Yr 5 Minutes 17 Wks/Yr 2 Wks/Yr 21 Hrs/Yr 4 Hrs/Yr 60 Min/Yr 5 Min/Yr 30 Minutes 10 Wks/Yr 2 Wks/Yr 25 Hrs/Yr 6 Hrs/Yr 30 Min/Yr 1 Hour 21 Wks/Yr 4 Wks/Yr 50 Hrs/Yr 12 Hrs/Yr 1 Hrs/Yr 6 Hours 25 Wks/Yr 5 Wks/Yr 1 Wks/Yr 6 Hrs/Yr 1 Day 20 Wks/Yr 5 Wks/Yr 24 Hrs/Yr 107

5S ❖ Do you have areas in your company that look like this? Its just like the first slide of chaotic numbers! 108

5S Shine “A clean workplace makes the unspoken statement that quality work is expected.” 109

5S Shine Cleaning is Inspection, Inspection is Detection, Detection is correction! 110

5S (‘Do’ Phase) 111 111

5S Standardize Good housekeeping habits should be everyone’s responsibility , including management and staff. STANDARDS (expectations) must be set and visual. 112

5S Sustain Requires self-discipline  Discipline is consistently working by the rules and standards of clearing, locating, and cleaning and commitment from everyone in the organization “Inspect what you expect” 113 113

5S Housekeeping Audit Scorecard Department:______________ Date:________________ Item 1 2 3 4 5 Comments Machine and surrounding workspace Tables & Desks Tool and other storage cabinets Drawing packages and other information packets Shop floor (tape areas) Total Grand Total Instructions: 1. Enter one of the numbers at the top of the column for each item. 2. Use the audit legend below for the meaning of each number 3. Total each column, enter the value, and sum these in the grand total space. 4. All areas are to be graded including assembly, sub-assembly, material storage, and the office areas. Audit Legend: 1. Not good. 2. Only necessary equipment is in the area. All other things have been disposed of or transferred to the appropriate department. 3. All necessary items are in their designated place. 4. The area is clean, free of debris and dirt. 5. Agreed upon procedures are posted, information is shared. 114

5S ❖ 1) Sort (Sort through & Sort ❖ 4) Standardize (and share out) information) ❖ Keep what’s needed -- ❖ Design and implement Visual eliminate what’s not… Controls ❖ 2) Straighten (Set-in-Order & ❖ Standardize tools and Set Limits) procedures ❖ Where shall we put it? How ❖ 5) Sustain (Self-Discipline) shall we store it? ❖ Train everyone to new ❖ 3) Shine (and inspect through standards cleaning) ❖ Audit system ❖ Clean it up and prepare to ❖ Continue to improve keep it clean. 115

Agenda ❖ Welcome and Introductions ❖ MLC Overview ❖ Introduction to Lean ❖ The 8 Wastes ❖ Personal Kanbans ❖ Standard Work Exercise ❖ Error Proofing ❖ 5S ❖ Kaizen ❖ Sustaining and Maintaining the Concepts ❖ What will you do Monday? 117

Kaizen —a Japanese term that means “improvement” or “change for the better.” Kaizen Event — A problem solving activity that engages a team in finding the root causes of a problem and/or identifying waste in a process, followed by developing experiments to improve the system to the mutual benefit of customers and employees. Typical Kaizen Goals Improved safety, quality, delivery, cost (sqdc) in that order…. NEVER to eliminate positions people will be reassigned if needed

Follows the problem solving model Plan ➔ Do ➔ Check ➔ Act Act Plan • Form a Team Check Do • Go and See (Go to the Gemba) The Problem = Gap between Current Conditions and Goal • Understand the Current Situation • Identify Waste and Unsafe Acts and Conditions • Look for Root Causes • Create Improved Process using some of the tools we’ve learned today (Personal Kanbans, Standard Work, Error Proofing, 5S) • Use Newspaper to Keep Track of Planned Work • Report Out

• Make work safer • Make work easier • Make work more interesting • Build skills and capabilities • Support strategic goals • Improve organizational engagement, learning, and growth

Agenda ❖ Welcome and Introductions ❖ MLC Overview ❖ Introduction to Lean ❖ The 8 Wastes ❖ Personal Kanbans ❖ Standard Work Exercise ❖ Error Proofing ❖ 5S ❖ Kaizen ❖ Sustaining and Maintaining the Concepts ❖ What will you do Monday? 122

Sustaining And Maintaining Improving your process exercise I need a Volunteer I am going to improve your process! 123