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Waste elimination processes
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COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
APR
REPORT CHK APR
Q’ Production Team
Nov’09
7 Waste Elimination Plan
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
7 – Waste ( Overview )
Our Objective > Value Added = Maximum
Non Value Added = Minimum
Productivity Output
----------------Input
=Output
----------------Minimum Input
=Output
----------------Input + Waste
=
> Why to Identify and Eliminate Waste ?
Eliminate to Improve Productivity
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
7 – Waste ( Overview )
1
2
3
4
5
Waste from Over Production
Waste from Over Processing
Waste of Waiting Time
Waste of Motion
Waste of Transportation
7 Waste of Inventory
6 Waste from Defects
List by Toyota
( Found in Manufacturing )
9 Mis-used Resources
8 Untapped Resources
11 Waste of Communication
10 Waste of TalentRecently added wastes
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
7 Waste Elimination Plan
Type of Waste Description Reason Action Plan Target Remarks
1. MotionOperator motion does not add value
Working height, work distance and work area more.
Study work area and improve the condition
Dec’09 Height – Nov’09
2. Over Production
Excess Quantity.
No confidence in Process, Setup quality, Equipment and make use.
Identify line wise excess production and do line balancing
Jan’10Top 10 parts will be taken
3. Over Processing
Non value added
Operators not clear what exactly to be done.
Auto mode check, observing process identify
Mar’10Top 10 parts will be taken
4. Waiting Operator / Machine
No multi skill, no preparation of matl and tools
Line stop system and start up system improvement
Feb’10
Line stop & Top 10 tool clamping problem will be taken
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
7 Waste Elimination Plan
Type of Waste Description Reason Action Plan Target Remarks
5. Transport
Distance between two machines / locations
Improper process flow, improper layout.
Layout change and elimination of temp storage.
Dec’09
Top 5 Machines will be taken
6. Defect Rework / rejection
Process itself produce defective which to be be reworked / scrapped
PPM Level study and Q chart use Nov’09
Top 5 parts will be taken
7. Inventory Holding of stock
Result of over production, Machine failures and defectives.
My machine concept & SAP system usage
Apr’10
Top 10 high inventory parts will be taken
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
Motion – 1 ( Man movement )
NO TASK
PLAN
STATUS TARGETCHARGE(TEAM)ACTIVITY
EFFECTAMOUNT
1 Working height standardisation
Studying existing work height and altering the area to standard
5,000 Data collected 15-11-09 Q.P.
2 Work distance and Arm movement standardsiation
Analysing all work area for standard distance and crate keeping location and operator turn position
20,000 To be started 15.12.09 Q.P.
3 Champions moving from the area .
Making system for calling support team for their requirement. ( Line stop alarm system )
2,50,000To be
planned10.01.10 Maint
COMPETE TO WIN 2009
Team Slogan – Think SSS ( Simple , Straight & Short )
7 Waste – Action Plan
Major activity Detail Action P/
A
Date ( Nov’09)Remarks
oct 1 2 3 4 5 6 7 8 9 10 11 12 13 1415-
20
Working Height system
1. Training to staff regarding working height
P
A
2. Making standard format for data collection
P
A
3. Collection of dataP
A
4. Compiling and analysis
P
A
5. Making implementation plan
P
A
6. Modification of working height
P
A
7. Making standard to all lines
P
A
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