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July '10, IDRO Seminar 0
Best Practice of
Use-Ware for
Improving Factory Operation
Mr. Hajime SUZUKI (Dr. Practice)Professional Engineer
authorized by Japanese Government
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Guidelines* for
Practical KAIZEN
*by Dr. Practice
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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3. Practical Approach
4. Basics of Production Management 1) Effective Problem Finding 2) Effective Problem Solving 5. Integrated Activities
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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1) Critical Issue Oriented, not Tool oriented
2) Start from Pilot (Model) Area, not company-wide from the first
3) Practice Basics with Intensive Effort not introducing sophisticated techniques/systems
3. Practical Approach
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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(1) Process Analysis (2) Stratification(3) 3 Gen ③find Fact (Genjitsu) ②by closely observing Actual thing (Genbutsu) ①at Site (Genba)
(4) 3 Mu ①Muda (waste) ②Mura (un-even: low and high in defect, etc.) ③Muri (un-natural, such as stacking too high, etc.)
4. Basics1) Effective Problem Finding
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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In addition to the aboveS (Safety) andM (Morale) should be examined.
Production (capacity)
Material
Product
Machine
Delivery
Supply
Process
Quality (check and control)
Cost (waste of material & man, etc.)
Delivery (waiting time, etc.)
Order
Planning,Scheduling
(1) Process Analysis
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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1) Pareto diagram
2) Cause & effect diagram
3) Histogram
4) Check sheet
5) Scatter diagram
6) Stratification
7) Control chart and Graph
Ordinary 7 QC Tools Practical “8 QC Tools”(in the order of effective use)
1. Stratification2. Check sheet
4. Histogram
5. Pareto diagram
6. Cause & effect diagram
7. Scatter diagram
3. Graphs
8. Control chart
(2) Stratification
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Genba (at Site): 1. Manufacturing Ind. Painting process, Assembly line, Inspection station, Material stockyard, Production floor, Product warehouse, Maintenance store, etc.
2. Non-Manufacturing Ind. 1) Restaurant: Guest dining room, Kitchen, etc. 2) Shop: Showroom, Sales floor, etc. 3) Transportation: Road, Station, Truck, Warehouse, etc.
'3 Gen'-1 (Genba, Genbutsu, Genjitsu)
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Genbutsu (Actual thing): 1. Manufacturing Ind. - Good Quality product, - Rejected parts, - Work instruction in Foreign language, - Semi-product covered with dust, etc.
2. Non-Manufacturing Ind. 1) Restaurant: - Table wares, - Foods, - Materials, - Cooking utensils, etc. 2) Shop: - Best selling goods (design/color combination), - Showcase, etc.
'3 Gen'-2 (Genba, Genbutsu, Genjitsu)
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Genjitsu (Fact): - Semi-product covered with dust Why with dust? - - staying 3 months Why staying so long? - - order was cancelled after produced Why cancelled after produced? - - this customer often gives uncertain order Why started production without confirming order - - followed general rule 'start as early as possible' Why followed general rule? - - there is no special rule for this kind of non-reliable customer
'3 Gen'-3 (Genba, Genbutsu, Genjitsu)
Link: Pipe Plant
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Muda : Waste 1) Waste of material - Defective products, - Start-up waste, - Design waste, - Dead stock, - Long staying stock. etc.
2) Waste of manpower - Idle time, - Over time, - Reworking, etc.
3) Waste of facility - Broken facility, - Excess facility, etc.
'3Mu-1' (Muda, Mura, Muri)
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Mura : Un-even Data: 1) Daily production very high and very low 2) Defects very low and very high
Operaton: 3) Driving very fast and very slow 4) Materials coming too much and too little 5) Machines stop frequently etc.
'3Mu-2' (Muda, Mura, Muri)
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Muri : Un-natural 1) Working un-easy posture 2) Carrying too heavy thing 3) Trying to reach too high, Working too much overtime 4) Driving too fast 5) Stacking too high etc.
'3Mu-3' (Muda, Mura, Muri)
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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(1) Best Conditions (2) Flow Production(3) Visual Control ① for right Management (report with high-lighting) ② for right Operation at shop-floor (in-line visual control) ③for promoting shop-floor activities
(4) PDCA ① for Daily Operation and management ② for improvement activities
Effective Problem Solving2) Effective Problem Solving
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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If 4Ms are good (normal), No defect will come out.
Good Methods
Good Machines and
Conditions
Good Men (Operators)
Good Materials
No Defect
(1) Best Conditions
Do your Best !
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Delivery : Delivery in Time
Finished Product : No Long Staying/Dead stock
Production
Material : No Long Staying/Dead stock
:Well controlled WIP Final process
・ ・
1st process
(2) Flow Production
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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(3) Visual Control① For Management “Visual Report” for managers to easily see important
points by highlighting with red color, etc. ② For Shop-floor Control “In-process (or in-line) Visual Control” for operators to easily follow work standard ③ For Shop-floor Motivation Visual Control posted on boards at shop-floor
Link: Case Machine (Visual Control-1)
Link: Visual Control 2
Link: Visual Control 3
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Plan, action Plan
2nd Target
Plan, action Plan*1
1st Target
(4) PDCA-2 (for Achieving Target)
Action*2
Check
Action=Helping to achieve target *2: and Appreciation
Plan=Target for improvement *1: and Preparation
Do=Improvement activitiesIn Do step, we have small (p)(d)(c)(a)
Check=Progress of improvement
Check
Do (a) (c)
(p) (d)
Do (a) (c)
(p) (d)
Action*2
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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PlanExisting level
(4) PDCA-1 (for Daily Operation)
Do=Daily operation
PlanBetter level
ActionDo
Check
Higher level
Plan=Existing system & method
Check=Result such as customer claim, reject, late delivery, etc. Action=Improve system & method
Action
ActionDo
Check
Action
Link: Case ISO Aplication.
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Case Study 1Best Practice
after
3-day Course and
Small-scale Consultation
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Best Participant In Suzuki's 'Practical IE' Course
Large variety of cushions for outdoor furniture exported to many European countries.
Link: Case Co. B
Top Mgt of Co. B attendedSuzuki’s IE course, thenSuzuki visited Co. B and gave guidelines on how toapply (Use-Ware).
She digested all what Suzuki gave, then applied them practically (developed her own Use-Ware).The case is prepared separately.
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Practical 5S 5S with Kaizen
developed through Suzuki’s 20 years experiences
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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In Japan, ・ 5S has been practiced for many years as common sense as Seiri Seiton「整頓整理」 for Safety, Quality, Efficiency then Environment. ・ In 1986, 1st book on 5S was published, since then 5S rapidly became popular. ・ In good companies, it has been continuously practiced and keeping high level.
History of 5S
In many countries, ・ 5S was successful during the initial period, however after a while, it easily become superficial, cosmetic and non-useful due to wrong application.
In Iran, - How is the situation?
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Ordinary 5S
Good for initial stage, but needs some modification for Practical use.
Seiri(整理): Sort out necessary items and un-necessary items, then discard un-necessary items.
Seiton(整頓): Arrange necessary items in good order so that they can be easily picked up for use.
Seiketsu(清潔): Maintain high standard of Seiri, Seiton, Seiso and workplace organization at all times.
Shituke(躾): Train people to follow good housekeeping discipline autonomously.
Seiso (清掃): Clean the workplace completely so that there is no dust on floor, machines or equipment.
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Objective Effective Problem Solving
•Best Conditions
•Flow Production
•Visual Control
•PDCA
PQCDSM
•Production capacity
•Quality
•Cost
•Delivery
•Safety
•Morale
•Customer Satisfaction
•Internal Effectiveness and Safety
•Profit •Happy Life
5S •Seiri
•Seiton
•Seiso
•Seiketsu
•Shitsuke
5S with Kaizen: always think Objectives
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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1. 1st stage: Ordinary 5S
Key point of Practical 5S
2. 2nd stage: Practical 5S Practice by thinking ”the objective of 5S at each work place” for Effective Problem Solving, namely, 1) Best Conditions 2) Flow Production 3) Visual Control 4) PDCA
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Practical Seiri: Sort out and remove un-necessary items and from the workplace.
What is the key point here ?
⇒Clear ‘Criterion’ and ‘Instruction’
Practical 5S: Modified by SUZUKI -1
“quantity (of necessary items)”
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Practical Seiton:Arrange - - for easy use (Location, Arrangement, Indication)
also must be in
“good conditions” (ready for use) in “fail safe ” (no chance of misuse, preventing any accident)
Practical 5S: Modified by SUZUKI -2
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Practical Seiso:Clean - - or equipment. Do it by considering the objective,
1) “collect dust without scattering” for clean workplace, 2) “remove dust without damaging product” for sensitive product,
3) “check and correct abnormal conditions” for machines and equipment.
Practical 5S: Modified by SUZUKI -3
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Practical Shitsuke:No modification, but for newly established factory, Rules, Regulations and Work Standards come first).
Practical Seiketsu:“Prevent from becoming dirty” and keep high level cleanliness“Maintain good hygiene”
Practical 5S: Modified by SUZUKI -4
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Case Study 2Best Practice
after
3-day Course x 2 timesand
6 times Consultation
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Best Participant In Suzuki's ‘Practical 5S' Course
When I showed this picture.Mr. A said ‘we are much higher level, I don’t need this’ and left the class with nothing.
On the other hand Mr. D, owner of apparel company, attended 2 times in the same course. He worked with Suzuki as model company and achieved good result. He went to Japan as an excellent participants. He cooperated in sharing his experiences in Practical 5S Course.
He was expecting what looks like this.
Link: Case Appael 2Link: Case Appael 1
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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Positive Mind
With your Positive Mind,Your dream will
come true !
Please surprise me with your
practice !
July '10, IDRO Seminar USE-WARE, Practical KAIZEN Prefesional Eng'r, Hajime SUZUKI
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