Continuous Improvement

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Continuous Improvement

• Wabash Manufacturing Systems

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What is Continuous Improvement ?

• A continuous process of working towards achieving
  incremental gains in the lean indicators using
  cross functional teams.
• Typical CI tools includes 5S, TPM, Standard Work,
  SMED, Variation Reduction, Safety and Ergonomics
  analysis, etc

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Lean Indicators and Definitions

• Lead Time the time from customer approval to
  perform work to delivery of completed work to the
  customer
• Inventory the amount of on hand materials
  needed to do the job
• Floor Space the amount of space needed to do
  the job
• Productivity - number of labor hours per order
• Distance Traveled- the walking distance per cycle

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The 4 Tenets of Employee Involvement

• Learn By doing
• Teach By doing
• Use the subject matter experts to obtain ideas
  and implement them
• By focusing on those adding value, you are
  focusing on the customer

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The 10 Commandments of Continuous Improvement

• Abandon fixed ideas.
• Think of ways to make it possible.
• No excuses needed.
• Go for the simple solution, not the perfect one.
• Correct mistakes right away.
• Use your wits, not your wallet.
• Problems are opportunities.
• Repeat Why? five times.
• Seek ideas from many people.
• There is no end to improvement.

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Profits are made or lost on the shop floor
plain and simple. -Bill Greubel Presiden
t C.E.O.
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5S at Wabash National

• A tool and strategy to develop improvement
  activities in our workplace.

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What is 5S?

• An easy definition is Finding a place for
  everything and putting everything in its place.
  5S is also the beginning point for continuous
  improvement (CI). Lastly, 5S is vital to our jobs
  and to Wabash Nationals security.

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What 5S isnt . . .

• A program
• A one time event
• Voluntary
• Something we tried before
• A cleanup to sell the branch
• Too hard because we are busy

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Why do we need 5S?

• We must be better today than we were yesterday,
  and better tomorrow than we are today Dick
  Giromini, C.O.O. Wabash National Corporation
• To remain in business we have to accept change
• 5S will allow us to reorganize and grow to be a
  stronger company

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5S is a tool to help eliminate Waste

• Transportation Parts delivered to a standard,
  mapped location.
• Overproduction One piece flow.
• Motion Place tools near the point of use.
• Defects Standard Operating Procedures.
• Waiting Balancing operator work.
• Inventory A min/max system to ensure the
  proper amount of parts are in the area.
• Process a clean, bright workplace to
  remove extra steps in process.

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48
45
87
72
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69
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9
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63
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81
Imagine this represents your shop floor, can you
find number 4?
42
39
66
84
90
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2
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77
86
62
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29
65
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41
20
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35
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89
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59
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10
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1
85
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82
25
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79
46
70
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What does 5S stand for?

• Sort (Seiri)
• Set In Order (Seiton)
• Shine (Seiso)
• Standardize (Seiketsu)
• Sustain (Shitsuke)

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What does SORT mean?

• SORT means we remove all items from the workplace
  that are not needed for current production
  (parts, tools, equipment, etc).
• Once we complete the sort process for tools in a
  work area, we must develop a standard list of
  tools that belong in this area and validate the
  area is kept free from non-needed items 30,60 and
  even 90 days from the initial sort.

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Imagine this represents your shop floor after
sort, can you find number 4 easier?
42
39
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29
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35
32
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Sort - Before and After
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Sort - Before and After
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What is SET IN ORDER?

• SET IN ORDER means we arrange items so they are
  easy to use, and labeling them so they are easy
  to find and put away. It begins with eliminating
  waste.
• Once we set in order for tools, we must
  standardize the locations for the tools and audit
  to the Set-In Order 30,60 and 90 days from the
  initial set in order.

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Imagine this represents your shop floor after set
in order with labeled racks, can you find number
7?
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36
15
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42
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Part 3,12,21,30,39,48
Part 9,18,27,36,45
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Part 8,17,26,35,44
Part 2,11,20,29,38,47
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28
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Part 7,16,25,34,43
Part 4,13,22,31,40
Part 1,10,19,28,37,46
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SET IN ORDER - Example
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SET IN ORDER - Example
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Set In Order Violations
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SET IN ORDER Before and After
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What is SHINE?

• SHINE means keeping everything swept and
  everything clean. It means keeping everything in
  top working condition so that it may be used when
  it is needed.
• Once we shine, we must standardize our
  housekeeping requirements and audit to this
  standard 30, 60 and 90 days from the initial shine

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SHINE - Example
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SHINE - Example
It takes everyone to succeed!!!
VP of Manufacturing Jerry Linzey
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SHINE
Example of Housekeeping Map
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What is STANDARDIZATION?

• STANDARDIZATION exists when the first three Ss
  are properly maintained. It means we develop
  methods to SORT, SET IN ORDER, and SHINE our
  workplace. It means we define everything so
  everyone will know exactly what we are
  responsible for and, exactly when, where, and,
  how to do it.

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Numbers from 1 to 49
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Imagine this represents your shop floor after
standardize, can you find number 7?
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STANDARDIZE - Examples
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What is SUSTAIN?

• We SORT areas. We SET IN ORDER work places. We
  SHINE areas. With STANDARDIZATION it is easy to
  identify anything out of place. SUSTAIN is
  different. It isnt a single separate activity.
  We SUSTAIN when we have developed habits of
  always using the first 4 Ss together on a daily
  basis.

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48
45
87
72
30
33
27
3
69
51
21
24
9
57
75
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6
78
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66
84
90
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68
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Imagine this represents your shop floor, can you
find which number is missing?
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Numbers from 1 to 49
Imagine this represents your shop floor, can you
find which number is missing?
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AREA BEING SUSTAINED
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AREA NOT BEING SUSTAINED
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What violations do you see?
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When does 5S happen?

• ALL THE TIME!! 5S is a mindset and a culture. The
  5Ss are a part of each Associates workday.
  There will also be CI Events. In an Event,
  Associates are taught how to implement the
  principles of Continuous Improvement.

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How will 5S be implemented?

• By the associates! Who has a better idea to make
  our jobs easier than us? Our management is
  committed to improving how we work. We want to
  work smarter, not harder. Along the way, support
  will come from EVERYONE, including a CI Team of
  Associates. We will teach the 5S process, and
  together we will implement it and make it work.

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Who is our 5S Team?

• CI Team
• Engineering
• Safety and Environmental
• Maintenance
• Human Resources
• Shop Floor Upper Management
• YOU!

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Benefits to Us Wabash National

• JOB SECURITY!
• We get involved in our company
• Our jobs become pleasant and satisfying
• Obstacles and frustration are removed
• We know our expectations

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Benefits to Us Wabash National

• Quality will improve
• Safety will improve
• Costs will be lower
• Our reputation will increase
• Profits will increase

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Our organization has made significant gains
in Safety, Quality and Productivity. A key
enabler to these gains has been improved
Workplace Organization also known as 5S, WPO or
simply Housekeeping. The improved organization
means not tripping over parts, being able to find
your tools, having clear aisles, installing the
correct parts, etc. Workplace Organization is
critical to our success. -Jerry Linzey VP,
Manufacturing and Continuous Improvement
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Continuous Improvement Summary

• It doesnt take an expert to implement CI
• It is not all about 5S, but 5S is usually a good
  place to start
• Employee Involvement Is CRITICAL to the success
  of CI.
• The employees will buy in quicker when they see
  the management team getting dirty too.
• Take the lean leap! Try it! If you fail trying
  to improve, then you successfully gained
  knowledge for your next try.
• Never stop Improving