EFFECTIVE SHOP FLOOR ORGANIZATION

FOR MICRO & SMALL

FURNITURE MANUFACTURERS

Today you will learn:

1. How to organize your production space

2. Plan a better work flow

3. About the Factories act

4. How to keep a safe work environment

5. How maintenance of equipment can help you

Agenda Start End Time

Module 1 Operations Organization

Registration & introduction 9:00 9:30 0.50 hr.

a. Effective shop floor organization for small facilities: 2.5 hrs.

Effective layout options for small facilities 9:30 10:00 0.75 hr

Process Flow & Shop Floor Organization 10:00 11:00 1.00 hr

Coffee Break 11:00 11:15 0.25 hr

Space Utilization for efficiency including 5-S methodology 11:15 11:45 0.50 hr.

b. Safety for small furniture manufacturers: 3.5 hrs

Introduction to the Factories Act and OSHA Stds. 11:45 12:15 0.50 hr

Lunch 12:15 1:15 1.00 hr

Basic Equipment maintenance tips 1:15 1:45 0.50 hr.

Preventing Electrical Hazards 1:45 2:15 0.5 hr

Impact of lighting and ventilation on safety 2:15 2:45 0.5 hr

Wrap up and close 2:45 3:00 0.25hr

Total Workshop time 6.0 hrs.

EFFECTIVE SHOP FLOOR ORGANIZATION

WHAT HAPPENS IF YOUR SHOP FLOOR IS NOT ORGANIZED?

• You spend more time looking for things

• It is difficult to know how much waste you have

• It is hard to move around

• It is harder to produce quality work

• You can lose things and not know

• Space is wasted

• Everything is confusing

HOW CAN YOU SOLVE THESE PROBLEMS?

1. Proper LAYOUT of production space

Why do you need a proper layout?

The objective of facility layout id to locate people, machines and processes in a logical, time-saving and money-saving manner that meets anticipated production levels

1. Proper LAYOUT of production space

Some goals to achieve through layout design

1. Maximize the use of machine tools

2. Minimize labour requirements

3. Provide a smooth flow of materials and products

4. Minimize health hazards

5. Minimize material handling effort

6. Maximize the use of available space

7. Provide maximum flexibility to avoid “hiccups” in operations

8. Maximize output

Process

TYPES OF LAYOUT

Product or line

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Product or Line Layout:

Focus is on sequence of production or assembly of products

Ideal for Mass Manufacturing situations

Workstation sequence is fixed and does allow changes to production

Not flexible to product changes

Process Layout:

Group machines that perform similar or related functions together or close to each other, such as saws.

It allows flexibility in making several types of products at the same time

It requires careful production planning and material handling to avoid bottlenecks and delays in production

Process Layout:

Exercise:a. Name the different functions needed to make a side table:

_____________________________

_____________________________

_____________________________

_____________________________

Process Layout:

Exercise:b. Do a rough sketch to show how the materials flow from machine to machine:

Assume you have:

Table saw Miter saw Router

Jigsaw (or handsaw)Belt sander Clamps (for Shop note)Other hand tools

Process Layout:

“5-S”

Putting the “5-S” system in place to clean up & manage your shop floor

What is “5-S”?

The Five S program focuses on having visual order, organization, cleanliness and standardization.

The results you can expect from a Five S program are: improved profitability, efficiency, service and safety.

The 5-S concept originated in Toyota, Japan. - Factories in Japan are reputed for their cleanliness and orderliness. - This is due to their ability to instill a sense of responsibility and discipline into their workers, particularly at the plant (shop-floor) level.

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et in Order

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tandardize

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• Improves safety / Reduces accidents• Reduces downtime• Enhances operational control of processes• Creates a healthier corporate climate• Improves product quality• Improves efficiency and productivity• Improves delivery times and assists in reducing

costs• Creates a positive work environment• Improves customer perceptions

Some benefits of “5-S”?

SORT

Separate according to: •What Is Needed•Needed Later•Not Needed

Discard What Is Not NeededSeparate Needed Items By Frequency of use

Sorting is the first step in cleaning up your floor. It helps to identify things which are no longer necessary in the space.

SORT

Name 5 things in your work area which aren’t necessary.

When you return, make it a duty to remove them!

SORT

For items which are needed – identify where they should go.

For items non needed – remove them from the floor and into the garbage!

SORT

Exercise:

List some of the things you can think of in your own factory that can be thrown away?

SORT

Exercise:

List some of the things you can think of in your own factory that can be thrown away?

Old Tools & machines that will never work again

Scrap lumber and other odd pieces

Old drawings, patterns, etc

Old furniture that have not been worked on in over one to three months

BENEFITS OF SORTING

Keeps the work area clean and clutter free reduces risk of safety incidents

Creates “extra” work space where necessary items can be placed

Reduces time spent searching for tools and materials

Removing supplies, materials and paper work not required to do the work helps improve efficiency

Set in Order

Can also be called the STRAIGHTENING OR TIDYING UP stage.

At this stage you should now ORGANIZE everything.

Arrange items so that they are easy to find and can be accessed readily.

“A Place for everything and everything in it’s place”

Set in OrderUse tags and signs and other labels to identify where things should be kept.

Set in Order

For every item in the workplace we will need to:

Identify itAllocate a place and store itDetermine how much/how many to store at the work

place

Example of area marked out for items

Set in Order

• Decide where to keep needed items– Keep frequently used items at point of use– Screwdrivers next to screws

• Organize items in a way that makes sense– Make it easy for anyone to find them, use them and put

them back after use• Use outlines and labels

– Make it obvious when items are not in their correct place

Set in Order

• Decide where to keep needed items– Locate items according to their frequency of use (higher

frequency = closer to you)– Store items together if they are used together (i.e. –

ratchets with bolts)– Store them in the sequence they are used– Consider tools on retractable cords (overhead)– Simplify – use one tool for multiple functions

Set in Order

SOME BENEFITS OF SET IN ORDER

Safety is improvedClean clutter free floors and aisles

Tools and parts are stored properly so there’s less damageLess waste of motion – reduced searching for materials, tools & suppliesReduced inventory of materials, supplies

SHINE is all about cleanliness. Clean the workplace completely so that there is no dust, dirt or garbage on floor, machine, workbench etc.

SHINE

Shining results in a cleaner, safer and healthier workplace.

It helps to maintain the sorting and set in order steps done before

Shining requires discipline to maintain.

Everyone in the workshop should have the responsibility to “shine” their work areas daily.

SHINE

By constantly cleaning or “shining”, it will make it easier to inspect equipment and tools often.

When cleaning machines of sawdust, you can see if parts become loose, wires begin to break, etc.

This gives you a chance to correct any machine defect before it breaks down

Shining also lifts the morale and pride of persons working in the space, and will impress your customers a lot!

SHINE

To ensure Shining is done regularly:

Make a roster of who is to do what

Make a schedule of when the place is to be cleaned - for example: empty bins every evening; sweep the floor every morning; remove scrap wood once a week, etc.

Keep cleaning equipment (brooms, bins, brushes) in a easy to reach convenient spot.

Give the responsibility to someone to ensure “Shine” is done

It is important that It is important that we establish the we establish the

first 3S before we first 3S before we progress to the progress to the

next 2S.next 2S.

STANDARDIZE

Standardizing helps to Maintain a Serene Atmosphere

STANDARDIZE is the means by which we maintain the first three S’s, namely SORT, SET IN ORDER and SHINE.

- You should maintain high standards of housekeeping and workplace organization at all times.

Standardizing is about implementing BEST PRACTICES in the workplace

STANDARDIZE

Have a written manual or procedures on who is to do what, when, how and why is a part of standardization.

Develop a schedule that shows who has what responsibility.

Responsibilities should be a part of every day work activity

SUSTAIN

SASTAIN is the set of approaches to be used to win hearts and minds, to make people want to keep applying best practices in shop organization and housekeeping.

It is having the discipline to maintain the correct procedures and standards over time

It is creating conditions, or an atmosphere, that encourage the constant practice of good habits and the elimination of bad ones

RECAP

• Sort – to put things in order– Remove what is not needed & keep what is needed

• Set in order - proper arrangement– Place things in a way that they are easily accessible

whenever they are needed• Shine – clean

– Keep things clean & polished; no trash in workplace• Standardize

– Standardize best practices / processes for cleaning• Sustain – commitment and self-discipline

– Develop an attitude and culture that follows the other 4S’s

BENEFITS

• Reduced set-up times• Reduced cycle times • Reduce searching time• Increased floor space • Reliable Delivery

• Less wasted labour

• Better equipment reliability

• Higher Quality

• Lower cost

• Lower safety incident/accident rate

The End

Jamaica Business Development Corporation.

14 Camp Road, Kingston 4

Tel: 928-5161-5

Or

76 Marcus Garvey Drive, Unit 10A

Kingston 13

Tel: 923-4729