Download - Final pres lean[2]
Team members: Dhruv, Rijul Daga, Riyanka Daggubati, Hitesh
Department of Manufacturing System &
Engineering Management
Instructor: Professor Hamid Gholami
3rd May, 2012
1S - SORT (Seiri)
Identifying unnecessary tools,
Red tagging, yellow tagging
2S – SET (Seiton)
Synchronize by item labeling,
color coding & markings
3S – SHINE (Seiton)
Cleaning, eliminating small imperfections
4S – STANDARDISE (Seiketsu)
Updating SOP
5S – SUSTAIN (Shitsuke)
Audits, newsletters, review meetings, goals
A place for everything
and everything in its place.
“Behind all workplace successes or
failures are the 5S” – Hirayuki Hirano
5S Event
“The value of performance”
Project Charter Problem statement
machine shop areas are not as organized for efficient work flow waste in space usage and raw materials damaged or unused tooling
MPD (Mechanical Production Directorate) plans to consolidate some machine shops,
and this is a preliminary step towards that consolidation.
Project description Within a kaizen framework, use 5S principles to specific work areas and organize,
clean, standardize and sustain 5S
Project Target/Objectives Apply 5S to specific areas in MPD M3 first floor mechanical fabrication areas only
Scope In : M3 First Floor Mechanical Fabrication Production Areas Out : Office areas on same floor, NO MOVEMENT OF FLIGHT H/W
4
Schedule
5
M3 1st Floor – Areas to 5S
6
Area 1
Milling-1
Area 2
Milling-2
Area 3
Lathe &
Turn
Area 4
Sheet Metal
Fab
Area 5
Precision
Assembly
1 2 3 4
5
Lean Kaizen event
7
5S SUMMARY ASSESSMENT OF WORK AREA
Date scored: 11/18/05
ENTER AN OVERALL REPRESENTATIVE SCORE OF 0 TO 4 FOR YOUR SUBTEAM'S AREA
(Based on observations and results of interviews of area performers)
Score
Team 0 1 2 3 4 Comments
1: Milling-1 XNewer, high vol. Mostly needed org around workflow,
tooling racks, minor cleanup. Move machine Sat; heavy
duty storage already on hand- can accomplish lots Sat
2: Milling-2 X2 major areas of improvement: lead man room not needed,
rack of tooling, consolidation, scrutiny of tools, work area
layout. Red-tagged 29 items
3-Lathe & Turn X Area was very dirty and has some setup issues
4-Sheet Metal Fab X40--50 red tags. Area to be consolidated, moved into 202.
Focus on getting rid of things in prep for consolidation.
Move MRB cage
5-Precision Assembly X
Examined workflow including tower, currently in a location
away from the room. Plan to move mostly into room as
majority is small. Later feedback from Fred Deninger that
this area is slated to move to 202 anyways, so concentrate
more on sorting and organization and cleaning rather than
moving. Also saw some opportunities to ensure incoming
kits are correct before starting to work on them
Mitch - see if we can give some surplus equipment to employees legally
Overall, received constructive comments from area performers, very positive.
Mike McVey:, "Try to keep them engaged. People will want to keep a cleaner area clean."
Standard Kaizen Process
Develop the Plan Kaizen To-Do Lists developed for each sub team
8
# Actionee
Date
Asngd Due Date
Status
(Open or
Closed) Required Action
%
Done
Desired
Outcomes1 Mike, Pat 11/19/05 Saturday, November 19, 2005 Open Move EDM machine (multiple areas - same
functions)
Centralize
EDM
machines and
tooling
2 Elmo 11/19/05 Saturday, November 19, 2005 Open General cleaning of whole area
3 Pat, Luis 11/18/05 Saturday, November 19, 2005 Open Acquire heavy duty industrial shelving (have 1,
need 2 more)
Localized
area for
boxline tooling
and raw
material
4 Luis, Imre, Mike Open Optimize carts and raw material storage area Surplus
excess carts
and
standardize
storage of
carts
5 Allen 11/21/05 Tuesday, December 20, 2005 Open Tool holder storage for CAT-40's Safe place to
store tool
holders
6 Allen 11/21/05 Tuesday, December 20, 2005 Open In-process hybrid storage area Safe storage
of in process
flight
hardware
7 Allen 11/21/05 Tuesday, December 20, 2005 Open Acquire die card for boxline tooling Eliminate
storage for
tooling around
machine
8 Brian 11/19/05 Saturday, November 19, 2005 Open Optimize work benches Clean and
neat work
areas
# Actionee
Date
Asngd Due Date
Status
(Open or
Closed) Required Action1 Subteam plus
some other
people
11/18/05 Friday, November 18, 2005 Open Red tag cabinets by going through them. Get
some night shift people involved in sorting.
Create the red tag log. Determine what
cabinets can be eliminated or consolidated
2 Clements and
area performers
11/18/05 Saturday, November 19, 2005 Open Go through existing cabinets and identify what
to eliminate, redistribute, scrap and/or donate
tools
3 Subteam plus
some other
people
11/19/05 Saturday, November 19, 2005 Open Physically eliminate redundant and inefficiently
used cabinets. Move them
4 Subteam plus
some other
people
11/18/05 Saturday, November 19, 2005 Open Scrap the bookshelf and outdated manuals
5 Subteam 11/19/05 Saturday, November 19, 2005 Open Go through Storage rack to eliminate tools,
clean, reorganize rest of tools. Move items
Saturday
6 Otera 11/18/05 Friday, December 02, 2005 Open Eliminate blanketed area formerly known as
the lead man office area
7 Clements 11/18/05 Saturday, November 19, 2005 Open Get right people together including subteam 1
to re-layout area mentioned above as well as
adjacent areas to be more efficient per
markup.
8 Otera 11/18/05 Friday, December 23, 2005 Open Do new CAD layout for all areas needing new
layouts
9 Clements 11/18/05 Tuesday, November 29, 2005 Open After doing relayout, identify cabinets/shelves
for purchase (common tooling and material for
shop aids)
10 Clements, Otera 11/18/05 Friday, December 02, 2005 Open Investigate cost of supplying common
expandable tooling for machinists into tool
benches for day and night shifts to use
11 Clements 11/18/05 Tuesday, November 29, 2005 Open Ask for people to volunteer things out of their
work benches and toolboxes for common
shared use, get rid of scrap
12 Clements 11/18/05 Tuesday, November 29, 2005 Open Evaluate feasibility of setting up a vending
machine to vend out nuts, bolts, clamps,
common things used by machinists not
already in vending machines. Recirc back into
machine for shared use after checking it out
13 Clements 11/18/05 Tuesday, November 29, 2005 Open Come up with a simple process to establish
key contacts on each shift to make them
responsible for issue. Sign off sheets. Put
back into locked cabinets. Tied into above
action item
14 Clements, Otera 11/18/05 Thursday, December 08, 2005 Open Identify any facility fixes that need to be done
15 Clements, Otera 11/18/05 TBD Open Implement facility fixes identified above
16 Clements, Otera 11/18/05 Friday, December 02, 2005 Open Cost the move of heat treating oven to welding
room. Do in conjunction with precision
assembly heat treating oven
2 Ritchie 11/18/05 Friday, December 02, 2005 Open Get facilities support for disconnect,
movement and surplus of machines
3 James 11/18/05 Friday, December 16, 2005 Open Contact junior colleges for donation of
machines (e.g., El Camino, Compton, etc.)
4 Ritchie, Otera 11/18/05 Friday, December 16, 2005 Open Work with facilities for replacing floor where
machines broke flooring. Include asbestos
abatement as needed
5 Laverty 11/18/05 Friday, November 18, 2005 Open Create and review new draft layout of area 50%
6 Ritchie 11/18/05 Friday, December 02, 2005 Open Implement new layout
7 Ritchie 11/18/05 Saturday, November 19, 2005 Open Move, discard, reorganize, condense cabinets
(~12)
8 Ritchie 11/18/05 Friday, January 13, 2006 Open Work with facilities (plumbers, electricians,
etc.) to re-connect machines after they are
moved
9 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate purchase of new horizontal
bandsaw/cut-off
10 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate getting better vertifical bandsaw
from machine shop consolidation activity
11 Ritchie 11/18/05 Friday, January 13, 2006 Open Investigate replacement for Nomura horizontal
milling machine with a VTL to be able to do
horizontal and vertical work including a cost-
benefit analysis
12 Ritchie 11/18/05 Friday, December 16, 2005 Open Procure raw stock storage devices with
labeling
13 Clements 11/18/05 Friday, February 03, 2006 Open Create a clean area policy including
communication/training
14 Ritchie 11/18/05 Friday, December 16, 2005 Open Replace benches with modular benches to
support ergonomic use including computers.
Ensure they also have lighting on cabinets
15 Ritchie 11/18/05 Friday, December 02, 2005 Open Establish a centrally located cabinet for lathe
tooling
16 Ritchie 11/18/05 Friday, December 23, 2005 Open Get new vending machine for dispensable
tooling for the lathing area only
17 Ritchie 11/18/05 Friday, December 23, 2005 Open Move vending machine to lathe area
18 Ritchie 11/18/05 Friday, December 02, 2005 Open Get lathing team together to define shared
tooling to put into the vending machine
colocated with the lathing area
19 Ritchie 11/18/05 Friday, December 16, 2005 Open Identify and purchase a screen for mazak
manual lathe to vent chips from scattering
20 Ritchie, Connor 11/18/05 Saturday, November 19, 2005 Open Relocate hazardous waste flammable cabinets
that do not belong to this area
21 Ritchie 11/18/05 Friday, November 18, 2005 Open Get night shift crew to start sorting through
cabinets, empty out what is not needed. Start
cleaning up area as prework for Saturday
22 Ritchie 11/18/05 Friday, December 16, 2005 Open Work with facilities to replace burned out
lightbulbs. Investigate possibility of lowering
lamps
23 Ritchie 11/18/05 Saturday, November 19, 2005 Open Work with other areas (milling 1)to see what
they want from what is being eliminated from
this area
24 Ritchie 11/18/05 Saturday, November 19, 2005 Open Complete cleanup, identify what cannot be
done Saturday that should be created as
separate action items post event
# Actionee Date Asngd Due Date
Status
(Open or
Closed) Required Action
%
Done Desired Outcomes
1 Facilities 11/18/2005 12/31/2005 Open Remove MRB Cage Open space
2 11/18/2005 1/31/2006 Open
Remove shelves & cabinets in
inspection staging area Open space
3 11/18/2005 1/31/2006 Open
Move storage shelves against flow
tunnel wall Open space
4 11/18/2005 1/31/2006 Open
Add caging material to storage
shelves in new inspection staging area Security
5 11/18/2005 1/31/2006 Open Move inpection items to new area Open space
6 11/18/2005 2/28/2006 Open
Move center and south wall storage
shelves toward east wall Open space
7 Facilities 11/18/2005 2/28/2006 Open Move rotary blue tower (rolodex) east Open space
8 11/18/2005 2/28/2006 Open Rremove blue roller cabinet Open space
9 11/18/2005 2/28/2006 Open
Remove copy machine, conf room
table, courier shelf Open space
10 11/18/2005 2/28/2006 Open
Relocate tracker computer and
remove workbench & excess packing
materials Open space
11 11/18/2005 3/15/2006 Open
Move area control person to
inspection area and remove the area
control booth Open space
12 11/18/2005 2/28/2006 Open
Remove 3 storage cabinets outside
packaging area Open space
13 11/18/2005 2/28/2006 Open
Relocate packaging area next to
router staging area Open space
14 Team 11/18/2005 11/19/2005
Remove red-tagged "unused" sheet
metal machinery Open space
15 Movers 11/18/2005 TBD
Move red-tagged but required
machinery to M1 Open space
16 Team 11/18/2005 11/19/2005
Clean sheet metal area - pick up and
throw out unneeded "junk" Clean work area
17 11/18/2005 11/19/2005
Clean out router staging area - e.g.,
scrapped sheet metal Open space
18 11/18/2005 11/19/2005
Move crates in router staging area to
dock area Open space
# Actionee
Date
Asngd Due Date
Status
(Open or
Closed) Required Action
%
Done1 Team 5 11/18/05 Tuesday, November 29, 2005 Open Red tag cabinets by going through them.
Create the red tag log. Determine what
cabinets can be eliminated or consolidated
2 Team 5 11/18/05 Saturday, November 19, 2005 Open Go through existing cabinets and identify what
to eliminate, redistribute, scrap and/or donate
tools
3 Team 5 11/19/05 Saturday, November 19, 2005 Open Physically eliminate redundant and inefficiently
used cabinets. Move them
4 Team 5 11/18/05 Saturday, November 19, 2005 Open Scrap the bookshelf, bulletin boards and
outdated manuals
5 Team 5 11/19/05 Saturday, November 19, 2005 Open Go through cabinets, create min/max cabinets,
clear off the rock to eliminate seldom used
tools, red tag unused tools, clean, reorganize
rest of tools. Move items Saturday using
existing storage
6 Team 5 11/18/05 Saturday, November 19, 2005 Open Define and error and identification and
corrective action process
7 Team 5 11/18/05 Friday, December 23, 2005 Open Do new CAD and work station layout for all
areas
8 Team 5 11/18/05 Tuesday, November 29, 2005 Open Request ergo review of individual work
stations through health services to address
deficiencies including flat screen to maximize
efficiency
9 Team 5 11/18/05 Team 5 Open Reduce conveyance to Precision Assembly
from Towner's tower--move workable inventory
into area
10 Team 5 11/18/05 Friday, December 02, 2005 Open Examine RF work stations at Bldg 108
warehouse for potential use in precisions
Assembly
11 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Ask for people to volunteer things out of their
work benches and toolboxes for common
shared use, get rid of scrap
12 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Evaluate feasibility of setting up a vending
machine to vend out parts. Recirc back into
Precision Assembly for shared use after
checking it out
13 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Replace missing fluorescent light bulbs above
occupied work stations
14 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Clean/replace flooring tiles. (Asbestos tile)
15 Paul/Norm 11/18/05 Monday, November 28, 2005 Open Replace bulletin board with scrolling message
board
16 Paul 11/18/05 Monday, November 28, 2005 Open Replace lead desk with unigroup table, return
and table for staging area to improve
organization
17 Paul/Norm 11/18/05 Friday, November 18, 2005 Open Ask M&P to help identify an alternative to
using typewriter for electro chemical etching so
we can throw out typewriter!
Milling-1
Milling-2
Lathe & Turn
Sheet Metal Fab Precision Assembly
All actions closed as of 5/23/06
M3 5S Lean Event
9
Tool Storage rack
Before During
Sort, Shine Time spent looking for support tooling (MUDA)
After
Set in order, standardize
M3 5S Lean Event
10
Before After
Equipment relocation to improve work flow
1. End of the day debriefs
Initial 30 day review – 6th January 06 Final review – 22nd May 2006
11
4
38
08 512
915
519
812 31
104
0
20
40
60
80
100
120
140
Planning
& Mgmt
2-Milling2 4-Sheet
Metal
Total
Open Closed
Closed,
104, 77%
Open, 31,
23%
Closed,
135,
100%
Open, 0,
0%
Team #1 Milling1 Completed all action items; moved, cleaned, installed shelving, organized
Team #2 Miling2 Accomplished ~50% action items; rest are investigative, longer term
Team #3 Lathe & Turn Got rid of lots of old cabinets
Team #4 Sheet Metal Fab Moved shelves down about 40 feet, clearing much space
Team #5 Precision Assembly About 50% of actions, rest are longer term including computers, monitors.
2. Reviews
Implementation Updates
1. Freed square footage area – 4250
12
File: PSC MPD Mech Fab 5S Lean 11-19-05_ROM METRICS AND SAVINGS.xls
• 93% reduction in motion
• Total cost benefit - $527k
• Increased employee morale and efficiency
• Reduced workplace accidents
Conclusion and Results
Space Freed By Eliminating Non-Value Added items
13
Case Study – 2 MaST - Australia
Introduction Management consultancy and training
Found in 1971, Australia
Focuses on four main skills
Applying 5S Sort (Organize)
Set (Neatness)
Shine (Cleaning)
Standardize
Sustain (Self-discipline)
Transition
Reflection and learning
Link between 5S and strategic business plan
Changes in the internal cultures of the organization
Lesson for the international group
Conclusion
5S was incorporated in strategic business plan
Increased the morale of the employees
MaST