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Expose Problems
CI
Solve Problems
Continuous Improvement
Continuous Improvement is an integral part of successful manufacturing in todays competitive environment. It can help your company Reduce waste Increase efficiency Improve quality Reduce cost
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Continuous Improvement is systematically identifying and eliminating waste, as quickly as possible, and at the lowest possible cost.
Eliminate Bottlenecks
Bottleneck processes are individual processes or tasks that take more time than other processes and slow production. Continuous Improvement workshops 60 focus on waste 48 reduction and 50 Takt Time work rebalancing 40 35 33 to eliminate 30 bottlenecks.
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Visual Management
Being able to quickly identify and respond to abnormal conditions is critical to managing a manufacturing environment. Visual Management tools are improved to
Increase awareness and response Allow for quick return to stable conditions
Reduce Fluctuation
Unstable processes are difficult to staff and manage and inherently create waste in the production environment. Identifying and reducing process fluctuation
Reduces overall production time Increases visual management Allows for better allocation of resources
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Increased Knowledge
Tools learned during Continuous Improvements: 1. 2. 3. 4. 5. 6. 7. Practical Problem Solving Time Measurement Elemental Wall Ergonomic Checklist Standardized Work Process Stability Checklist 5S
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Reduced Costs
Traditional cost - plus approach
PROFIT Add desired profit to costing in order to determine selling price
MARKET PRICE
COST
PROFIT
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Increased Efficiency
We Gain Efficiency Through:
Process vs. Results Time Measurement Speaking with Data
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Improved RESULTS can only be obtained by improving the PROCESS. Process is NOW.
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Standardization
Best, easiest, safest way known today Basis for training Basis for relentless root cause analysis By standardizing processes, consistent results are produced in Safety, Quality and Efficiency Documentation of know-how
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Safety
A safe work environment is one of the cornerstones of a successful business.
Continuous Improvement supports the idea that no change should ever be made to a process that has a negative impact on safety!
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Quality
There are quality standards and expectations demanded of any manufacturing product. Changes to the process should never decrease the quality of the product provided to the customer!
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Ergonomics
The ergonomic impact of work should always be examined to see if improvements can be made.
Part presentation that places heavy or awkward parts within proper ergonomic levels can decrease waste of motion and fatigue.
Any changes to tools or processes should be analyzed with a critical eye towards any impact on ergonomics.
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Lean
Lean Manufacturing focuses on the identification and elimination of the 7 forms of waste:
Overproduction Inventory Unnecessary Motion Transportation Waiting Overprocessing Defects/Repair/Rework
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5S
5S improves organization, visual management, and standardization. The 5S status of an area is assessed in the first CI Workshop to help identify potential problems and 5S should be maintained as improvements are made.
SIFT SWEEP SORT
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SANITIZE SUSTAIN
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The CI Workshop
An activity/event to identify and implement improvements in a designated area A Standard method for Process owners, Supervisors and Engineers to focus and learn about waste elimination methods and activities An organized group of Team Members who identify and eliminate production wastes through Continuous Improvement activities A method for training groups of Team Members on the Continuous Improvement process
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C. I. Workshop:Team Roles
A group of motivated people with complementary skills and knowledge who are committed to a common purpose, set of performance goals, and approach for which they hold themselves mutually accountable.
Team Leader - point of contact, organizes agenda and activity, orchestrates team activities, keeper of all documentation, also a team member Team Members - contribute fully to the project, share knowledge and expertise, participate in all activities and discussions, carry out assignments Facilitator/Advisor - provides technical or planning assistance, provides training, focuses on the teams process (how) rather than product (what), works with team to eventually become self-reliant
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Team members should be available on line while changes are being made to help and answer questions.
Any required change documentation / approvals should be completed according to company policy Any required process training should be conducted prior to change implementation.
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Seconds
Reduced total cell cycle time from 259 seconds to 221 seconds
Reduced manpower by 1 operator per shift Increased cell utilization from 77.1% to 88.4%
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Seconds
Moving Forward
Train more employees in Continuous Improvement. Build a Continuous Improvement Team. Spread Continuous Improvement to other production lines or other areas of the plant. Build a culture of Continuous Improvement within your organization.
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Create a sense of urgency Have a vision, communicate it continuously Focus on key process drivers
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Non-Judgmental / Non-Blaming
Eliminates the search for who to blame Provides system improvement opportunities Allows relentless root cause analysis Increases trust Improves quality of communication Avoids shoot the messenger mentality Avoids crisis orientation
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