Lean Manufacturing

Wow!  With each improvement made, the GEMBA becomes a little brighter as waste (muda) and disorder are reduced.  Recent 5S tours have been encouraging.  Of course improvement opportunities were spotted and action taken; but for the most apart, we are holding on to improvements you’ve already made during 5S events, etc.

In order to keep improving (TOC step #5), it makes sense to continue follow-ups.  This is the “Sustain” step of 5S. . . .and since the people who work with a process know it best, who better to review progress?   Therefore, each area has been asked to implement a “5S Tour” at least weekly.  Take a good look around...imagine zero waste/zero confusion!

    Ten Kaizen Principles

1. Get rid of all old assumptions.
2. Don't look for excuses, look for ways to make things happen.
3. Say "NO" to the status quo.
4. Don't worry about being perfect - even if you only get it half right " start NOW!
5. It does not cost money to do KAIZEN.
6. If something is wrong "Fix it NOW.
7. Good ideas flow when the going gets tough.
8. Ask "WHY" five times - get to the root cause.
9. Look for wisdom from Ten people rather than one.
10. Never stop doing KAIZEN.

    5S

• Sort - All unneeded tools, parts and supplies are removed for the area
• Set in Order - A place for everything and everything is in its place
• Shine - The area is cleaned as the work is performed
• Standardize - Cleaning and identification methods are consistently applied
• Sustain - 5S is a habit and is continually improved

Also - Work areas are safe and free of hazardous or dangerous conditions

More information on 5S.

5S  EXAMPLES  OF  SUCCESS

• Maintenance-April 2002
• Machining-July 2002
• Quality Assurance-July 2002
• Quality Assurance (before and after pictures)
• Tool Room-August 2002
• Tool Room (before and after pictures)
• Finishing-September 2002
• Finishing (before and after pictures)
• Stock Room-October 2002
• Plant-Wide 5S Event-December 2002
• Web slide show of the Plant-Wide 5S event on December 2002
• TOC and 5S at work at the Tap and Plug Operation
• Die and Storage Areas-March 2003
• Areas Behind the Building-May 2003
• Mini 5S event of office storage areas-May 2003
• Die Setup Area-June 2003
• 2004 5S Event Schedule-Finishing, Tool Racks, Stockroom, Maintenance, Outside, Millwater, Restrooms, Vibratory, Machining, Tool Room, Quality, Die Casting, Furnace, Shipping and Office
  
  Examples provided by: Texas Die Casting
  
  [top]     [back to main page]
  
  Note on printing the pages above. To get the complete picture on the right side of the screen set the right margin to .25 (Internet Explorer-File, Page Setup - adjust the right margin to .25)

EXAMPLES OF MUDA (waste)

(Note: These links are to files in powerpoint)
• Missing paperwork creates muda
• Missing payroll check creates muda
• Birthday card muda
  Also included is how these muda problems were resolved using the TOC 5 step form.

OTHER

• Providing operator tools increases throughput (TOC & Lean)
• 5S of a home closet

Need help getting organized?

• the clickable house - house tips
• the clickable office - office tips