20 Keys to Workplace Improvement

1
20 Keys to Workplace Improvement

• Key 1 Cleaning and Organizing
• Key 2 Rationalizing the System/MBOs
• Key 3 Improvement Team Activities
• Key 4 Reducing Inventory (Shortening Lead
  Times)
• Key 5 Quick Changeover Technology
• Key 6 Manufacturing Value Analysis (Methods
  Improvement)
• Key 7 Zero Monitor Manufacturing
• Key 8 Coupled Manufacturing
• Key 9 Maintaining Equipment
• Key 10 Time Control and Commitment

2
20 Keys to Workplace Improvement

• Key 11 Quality Assurance System
• Key 12 Developing Your Suppliers
• Key 13 Eliminating Waste (Treasure Map)
• Key 14 Empowering Workers to Make Improvements
• Key 15 Skill Versatility and Cross Training
• Key 16 Production Scheduling
• Key 17 Efficiency Control
• Key 18 Using Information Systems
• Key 19 Conserving Energy and Materials
• Key 20 Leading Technology and Site Technology

3
Key 1 Clean and Organize

• Level 1
• Cigarette butts, scraps of paper, and tools are
  scattered about
• Level 2
• Clutters and piles of dirt lie against the walls
• Passageways are not cleared
• Unused items lean against walls
• Unused tools or equipment lie around
• Level 3
• Walkways are clear and the factory is clean, but
  the storage areas are disorganized
• Cabinets are locked and contents mixed together
• Level 4
• Machinery and equipment are clean

4
Key 1 Continued

• Level 4 (continued)
• Storage areas are clearly distinguished, and show
  parallel lines and right angles
• Cabinets are unlocked
• Level 5
• Everyone cleans regularly
• The work area is immaculate and tools are laid
  out squarely

5
Key 5 Quick Changeover Technology

• Level 1
• Current operating belief is that lot sizes should
  be large enough to reduce the number of
  changeovers
• Level 2
• Some employees have received quick changeover
  training
• Setup time on all bottleneck equipment has been
  reduced by 90
• Level 3
• All manufacturing employees received quick
  changeover training
• Setup time on all processing equipment has been
  reduced by 90
• Level 4
• Setup time is reduced to under 10 minutes on all
  equipment
• Level 5
• Changeover time is less than time required to
  produce 1 cycle (part)