Lean Manufacturing 2

1
Lean
Manufacturing
Visual Systems
2
Lean 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
3
Visual 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.

4
5S
Method for creating and maintaining an
organized and clean workplace.
5
(No Transcript)
6
1S - Sort - Seri
Separate and Discard
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1S - 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.

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2S - Stabilize - Seiton
Set in Order Straighten Arrange and identify
for ease of use
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2S - 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.

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2S 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,

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3S - Shine - Seiso
Clean up Scrub
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3S - 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.
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4S - Standardize - Seiketsu
Keep Clean
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4S - Standardize - Seiketsu

• Implement a plan to keep the workplace clean all
  the time
• No unnecessary items, mess, dirt
• Who?
• When?
• How?

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5S Schedule
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5S - Sustain - Shitsuke
Motivate
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5S - Sustain - Shitsuke

• Commitment
• Adherence
• Cell meets 5S principles at the end of each shift
• 5S Daily Checklist

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5 Minute 5S