1 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 1 Guidelines* for Practical KAIZEN *by Dr. Practice
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1
July '10, IDRO Seminar 0
Best Practice of
Use-Ware for
Improving Factory Operation
Mr. Hajime SUZUKI (Dr. Practice)Professional Engineer
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.
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
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.
(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
(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
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.
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
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.