Professional Documents
Culture Documents
Kai + zen
(Change for the better)
• Identify a problem
• Brainstorm with employees
• Make the improvement
• Monitor results
• Adjust as necessary
• Apply to like processes
3 Preparation 1 hr
4 Kaizen event 5 days
5 Follow-up 4 hrs
6 Follow-up & closeout 4 hrs
Kaizen event
3/27/2018 completed
© 2009 RLM & Associates LLC 8
Pre-Event: People
• Project Leader
• Lean Champion
• Team Members
Order to Produce
Be colorful with
Employee involvement and signs, displays and
visuals
management support
is CRUCIAL!!!!
2. Decreased Inventories
4. Improved Morale
Special Notes:
· Any product design changes must be approved, in advance, by the Tiny Tag
Company marketing department.
· All components must be produced in-house. No sub-contracting is allowed.
Reviewed by Management
Operating Instructions
Tested on the line BEFORE use
Operator 1
Operator 3
7
Operator 2
4 1
Approved by QA
8 5 2
9 6 3
Visual Aide:
Position of screws: Stainless Steel screws on Left staging shelf/Black screws on Right
Customer Demand
6 Month average = 20,000 units/month
• Improve Productivity
• Reduce breakdown leading to Zero
breakdown concept
• Leads to multi-skilling of workers
• Better safety
• Improve quality of products
Customer Demand
6 Month average = 20,000 units/month
48
Use Takt
40
Time/Cycle
32 Time Bar Chart
How
many
0 seconds
Are they working 100% of the time now? If not what portion of the time are they working?
3/27/2018 © 2009 RLM & Associates LLC 91
RLM & Associates LLC
Your Lean Six Sigma & Project Management Trainers Improve Leveling
Level Production
Level production allows organizations to build to the varying demands
of the customer while holding minimum inventories and causing
minimum delays
Start with the final mixed requirements to schedule the raw materials
needed Just-in-time
Combine build for stock orders with customer orders to level workload
# Description (seconds) 1 2 3 4 5 6
1 Bottom sheet
19 19
2 hoist 19 31
3 Box 12 38 12
19
4 Rubber Guards 7 59
18
5 Escutcheon Guard 4 28
6 Literature 7 120 31
41
7 Top Sheet 10
20
8 1st Strapper 10
32
9 2nd Strapper 10 22 22