Kaizen and Kaizen Event Implementation

Transcription

1 Kaizen and Kaizen Event Implementation Chris A. Ortiz PRENTICE HALL Upper Saddle River, NJ ' Boston Indianapolis San Francisco New York Toronto Montreal London Munich Paris Madrid Capetown Sydney Tokyo Singapore Mexico City

2 Contents Preface xi Acknowledgments About the Author Introduction xix xv xvii Part I Kaizen Basics 1 1 Kaizen and Kaizen Events 3 Kaizen 4 People of Kaizen 5 Leaders of Kaizen 5 Benefits of Kaizen 7 Kaizen Events 8 / Common Mistakes Made in Kaizen Events 9 Metrics 12 2 The Company Kaizen Program 17 Kaizen Event Steering Committee 18 Plant or General Management 19 Manufacturing Engineering Management 19 Quality Management 20 Operations or Production Management 21 Human Resource Management 21 Maintenance or Facilities Management 22 Purchasing or Materials Management 23

3 Production Supervisor 23 Operator Representative 24 Introducing the Kaizen Champion 24 Tracking 25 Kaizen Event Selection 26 Date and Length 28 Kaizen Event Team Leader 28 Kaizen Team Members 28 Preplanning and Preplanning Responsibility 29 Pre-event Goals 30 Actual Results 30 Event Budget and Event Spending 30 Action Items, Responsibility, and Status 31 Kaizen Communication 33 Kaizen Communication Boards 34 Kaizen Newsletter 34 Kaizen Suggestion Box 35 3 The Kaizen Champion 39 Why a Kaizen Champion? 40 Kaizen Champion Skill Sets 41 The Seven Wastes 41 Lean as a Business Model 42 5S and the Visual Workplace 42 Kaizen and Kaizen Events 43 Data Collection 43 Setup Reduction and Quick Changeover 45 Line Design and Work Flow 46 Material Replenishment 46 Project Management 47 Choosing the Kaizen Champion 47 Internal Option 48 External Option 48 Cost of a Kaizen Champion 49

4 Kaizen Champion Responsibilities 50 Training 50 Kaizen Monthly Meeting 51 Communication Boards 51 Kaizen Newsletter 51 Kaizen Suggestion Box 52 Kaizen Event Tracking Worksheet 52 Team Leadership 52 Action Item Follow-up 52 Monitoring Other Lean Initiatives 53 Alternatives 53 Why a Kaizen Champion? 54 4 Kaizen Event Scheduling 55 Four Weeks Before the Kaizen Event 56 Select the Process/Department/Work Area 56 Make a Tentative List of Kaizen Team Members 57 Select the Kaizen Event Team Leader 58 Establish Team Goals 59 Estimate Event Spending 59 Order Supplies 60 Update the Kaizen Communication System 61 Schedule Outside Assistance 61, Conduct Waste Analysis of the Area 61 Two Weeks Before the Kaizen Event 62 Finalize the Kaizen Team Members 62 Get an Update on Supplies and Outside Resources 63 Ask Team Members to Walk Through the Chosen Area 63 Pick a Room Where the Team Can Gather 63 Analyze the Collected Data and Start Coming Up with Design Ideas 64 One Week Before the Kaizen Event 64 Gather Current State Information 64 Meet with the Kaizen Team Members 65 Place All Supplies in the Team's Gathering Space 65

5 Meet with the Plant or General Manager 65 tf) [j Make Food Preparations 66 e Final Thoughts on the Timeline 66 Part II Kaizen Events S Kaizen Events 69 Four Weeks to Go 70 Select the Area 70 Select the Team Leader 70 Tentatively Select the Team Members 71 Establish Goals 71 Event Spending and Supplies 71 Update the Kaizen Communication System 72 Identify the Kaizen Team Meeting Space 72 Schedule Outside Assistance 72 Two Weeks to Go 72 Finalize Kaizen Team Members 72 Get an Update on Supplies and Outside Resources 72 Ask Team Members to Walk Through the Selected Area 73 One Week to Go 73 Gather Current State Information 73 Meet with the Kaizen Team Members 73 Place All Supplies in the Team's Meeting Room 74 Meet with the Plant or General Manager 74 Let It Begin! 74 Day One: Sort 74 Day Two and Day Three: Set in Order and Scrub 79 Day Four: Standardize 83 Day Five 84 Maintenance 5S Events 84 Day One: Sort 85 Day Two and Day Three: Set in Order and Scrub 86 Day Four: Keep Going 87 Day Five 87

6 5S Sustaining Tips 87 Create an End-of-Day Cleanup Procedure 88 Conduct a Daily/Shift Walk-through 88 % Establish a 5S Audit Sheet 88 Create and Maintain a 5S Tracking Sheet 89 Develop a 5S Incentive Program 90 6 Standard Work Kaizen Event 91 Preplanning 92 Effective Time 92 Volume Requirements 92 Takt Time 92 Process Analysis 93 Day One 98 Red-Tag Team 99 Review the Line Balancing Information 100 Completing the Red-Tag Event 101 End-of-Day Meeting 102 Day Two 102 Line Design 102 Midday Meeting 103 Scrub/Shine 104 ' Maintenance and Machine Shop Projects 104 Tool Presentation 104 Shadow Boards 105 Subassemblies 105 Day Three 106 Day Four 106 Creating Workstation and Parts Rack Signs 107 Floor Taping and Designations 108 Determining Subassembly Build Levels 108 Installing Shadow Boards and Tower Lights 109 Day Five 110

7 e 7 Case Study: Samson Rope Technologies, Inc. 111 January Kaizen and Kaizen Event Implementation Training 113 The Return Visit 114 Lean Assessment and Strategy Sessions 115 Samson Rope's Kaizen Program 116 Kaizen Steering Committee 116 Communication 116 Kaizen Event Supply Box 117 Monthly Meeting 117 Kaizen Event 1, May 7-11, 2007: Cell 5, Cell 8, and Splicing 117 5S Continued 120 Kaizen Event 2, September 24-28, 2007: Maintenance 120 Completing 5S 122 Kaizen Event 3, December 3-7, 2007: Coating Complete 124 Lafayette, LA: Lean Assessment 124 Kaizen Event 1, February 20-22, 2008: Large Rope Kaizen Event 2, April 7-11, 2008: Area G, Area D, Area B 127 Samson Rope Progress: Ferndale and Lafayette 128 Other Samson Rope Employees to Recognize Conclusion 131 <;. Index 133