Streamlining Processes via KaizenStreamlining Processes via Kaizen
Melissa Aquino
Agenda
• Kaizen Definition• Examples – Before and AfterExamples Before and After• Three Types of Kaizens
E l f CCWCD• Examples from CCWCD• Value Stream Map Exercise
Kaizen Definition• The Kaizen philosophy is drawn from the Japanese• The Kaizen philosophy is drawn from the Japanese
word kai which means “continuous” and zen meaning “improvement” or “wisdom”. g p
• The Kaizen management philosophy, therefore, is defined as making “continuous improvement”—g pslow, incremental but constant.
• Kaizen Events are when work groups set aside a few day or up to a week to simplify a process or work area - eliminating waste, creating space.
Before Kaizen
Components keptunder workstation
Before Kaizen
Tooling difficult tolocate due toi l b li dimproper labeling andclutter on shelf
After KaizenAfter Kaizen
• Tooling bins are easilyTooling bins are easily identified (tan) and each bin is labeled with a code number.
• Line operators refer to a tooling• Line operators refer to a tooling list that locates, based on a tool number, which bin contains the necessary tooling.
Mac-30 Line Standard WorkMac 30 Line Standard Work Sheet
STANDARD WORK SHEET STANDARD WORK SHEET
Crimp Cut Stake Stamp MaterialEvery Operation
Mac 30 Line
Press
Sand
Arbor
Every Operation
Mac-30 LinePackingInstall
SpringFinalAssy
SAFETY QUALITY STANDARD WIP WIP
ScopingReam Tap Drill Tooling
2
Kaizen Result SheetKaizen ResultsKaizen ResultsDepartment Name Mac-30 Line Date 26-Feb-02
Clutch Type 102-20-177 Takt Time 126Station
Identification
Goal Before Kaizen After Kaizen Total ChangeSpace (Sqare Feet) -50% 323 208 -36%
Inventory at Line -75% 91,635 16,000 -83%Inventory at Line 75% 91,635 16,000 83%Leadtime To Pull Job For Line -75% 1 Hour 5 min -92%
Crew Size -25% 4 2 -50%Scope Changeover (mins) -50% 40 20 -50%
Press / Drill Changeover (mins) -50% 35 10 -71%One good piece - Throughput -50% 4050 sec 78 sec -98%
Line Flow One Piece Batch 50 per One Piece n/aLine Flow One Piece Batch -50 per One Piece n/a
Remarks
DBS-0007 05/97
Types of Kaizen Events
• Value Stream Mapping• 5S – Simplify, Straighten, Scrub, Stabilize, Sustain. p y, g , , ,• Standard Work – One Piece Flow
What is a Value Stream Map?
• What is a Value Stream?A value stream includes all of the process steps (bothA value stream includes all of the process steps (both value added and non-value added) that are required to complete a product, service or task.
• What is a Value Stream Map?pVSM is a method that visually shows the material and information flows that help complete the taskp p
Value Stream Improvement &Value Stream Improvement & Process Improvement
Value StreamPROCESS PROCESS PROCESS
STAMP MACHINE ASSEMBLE
PROCESS PROCESS PROCESS
Raw
Customer
VALUE STREAM
RawMaterial Finished
Product
VALUE STREAM = All steps, both value added and Non Value Added, required to bring the product from raw material to complete
Mapping a Val e StreamMapping a Value Stream
C t St t F ll th f d t• Current State – Follow a path from end to beginning, and draw a visual representation of
h t h l it t k keach step, how long it takes, key resources.
• Future State – Draw a map of how value should flow. Opportunities to eliminate waste.pp
What VSM Does
VSM helps point out waste in a value streamwaste in a value stream, and then identifies the
K i t dKaizen events and projects that can
eliminate the waste.
20
8 Wastes
ZZZZ
ZZZ
x
Waiting
Quality Defects1,2,
3,4,5,6
1st
Unused Creativity
Transportation
Overproduction
Unused CreativityDe-Burring
O P i
Inventory
Over-Processing
Motion
One Piece Flow in a CellularOne Piece Flow in a Cellular Plant Layout
Significantly reduces transportation
Final Assembly
transportation, inventory, and waiting time while improving
Wave Solder
Testing
time while improving safety, quality, delivery, and costs.
Packing PC Board Assembly
C stomer Ra MaterialCustomer Raw Material
5S Is:What is 5S?
• A process to ensure a clean, orderly, safe and productive workplace.
• Foundation for FLOW and Standard Work.
1SSi lif
4SSt bili
5S5S
Simplify Stabilize
SUSTAINSUSTAIN
Straighten Scrub2S 3S
What Are the 5S’s?SSimplifyimplify
(S i i)Clearly distinguishing between what is necessary and what is unnecessary and disposing of the
What Are the 5S s?
(Seiri)
SStraightentraighten
and what is unnecessary and disposing of the unnecessary.
Organizing the necessary items so that they can be d d t d il(Seiton)
SScrubcrub
used and returned easily.
Cleaning floors, equipment, and furniture in all (Seiso)
SStabilizetabilize
areas of the workplace.
Maintaining and improving the standards of the first (Seiketsu)
SSustainustain
three S’s.
Achieving the discipline or habit of properlySSustainustain(Shitsuke)
Achieving the discipline or habit of properly maintaining the correct 5S5S procedures.
5SSUSTAIN5S
SUSTAIN
1SSimplify
4SStabilize
Simplify Straighten2S
Scrub3S
Clearly Distinguishing Between What is Necessary and
Simplify
Identify Truly Needed Items
What is Unnecessary and Disposing of the Unnecessary
Identify Truly Needed Items
– What is it for?
– Why do I have it?
How often do I use it?– How often do I use it?
– Does someone else have the same thing?
StraightenOrganize the Necessary Items So That They
Can be Used and Returned Easily
Straighten
Can be Used and Returned Easily
•• Place All Necessary Items in the Best Location and Visually Place All Necessary Items in the Best Location and Visually Organize the AreaOrganize the Area
– First decide where all items should be so that the organization is easy to use and understandg y
– Choose proper storage methods that minimize inventory and promote visual management
– Visually indicate locations so items is use can be returned– Visually indicate locations so items is use can be returned and missing items are easily identified
– Make sign boards that clearly explain inventory, equipment, and other items so anyone can understand the workplaceand other items so anyone can understand the workplace
StraightenStraighten
• Proper Locations
• Storage Methods• Storage Methods
• Location Marking
• Shadow Boards
• Sign Boards
Scrub• Cleaning Floors, Equipment, and Furniture in
ScrubCleaning Floors, Equipment, and Furniture in all Areas of the Workplace
• Establish a Clean Workplace• Establish a Clean Workplace.– Clean up the Area. Sweep & Wash Floors Sweep & Wash Floors Clean in, under, and around Equipment and Furniture Eliminate all Trash from Workplace
– Keep in mind: How do things get dirty? - Fix g g ythe root cause of the dirt.
StabilizeMaintaining and Improving the Standards
Stabilize
• Maintain and Improve the Clean, Organized Workplace
g p gof the First Three S’s
p g p
– Eliminate excess storage areas and flat surfaces– Make changes to equipment that make it easy and
quick to clean and eliminate dirt and leaks at theirquick to clean and eliminate dirt and leaks at their source
– Use check list to establish daily cleaning and organi ation acti itiesorganization activities
– Institute 5S5S Patrols to monitor 5S5S progress
SustainAchieving the Discipline or Habit of Properly
Sustain
• Develop a Habit of Simplifying, Straightening,
g p p yMaintaining the Correct 5S Procedures
p p y g, g g,Scrubbing and Stabilizing Your Workplace
• Everyone Has to Accept 5S as a Personal Goaly p
• People Follow Examples (Good and Bad); Set a Good Examplep