lean games

LEAN GAMES Prepared by Vishnu Jayakumar

Game Names5s study with an puzzle gameTime study & Lean Analysis of Torch Factory ApplicationTime and Motion Study using Plug Factory

5 S Puzzle Game

WHAT IS 5S ?

5S is a Japanese concept using five simple steps to create a conducive work atmosphere.

5S is a series of techniques that provide the foundation for a visual management system

5S - To create least waste way to deliver value to the customers

5S IS A WAY OF LIFEJAPANESE TERMS ON 5S

SEIRI OR SORT

SEITON OR SET IN ORDER

SEISO OR SHINE

SEIKETSU OR STANDARDIZE

SHITSUKE OR SUSTAIN

WHAT IS 5S ?5S

5S IS A WAY OF LIFE Sort Levels of Achievement

Factory Audit (2)

LevelSortIdentify & eliminate what is not needed

1Necessary and unnecessary items are mixed together in the work area.

2Necessary and unnecessary items are separated (excess inventory, Obsolete tools & Equip)

3All unnecessary items have been removed from the work area.

4Documented method to maintain work area free of unnecessary items.

5Waste is immediately visible and triggers a planned response with root cause analysis and corrective action.

LevelSet in OrderA place for everythingand everything in its place

1Tools, supplies and materials are randomly located.

2Designated location established for all items as needed.

3Designated locations are marked to make organization more visible (color, outlines, labels, numbers, etc).

4Documented method of visual sweep to identify items out of place or exceeding quantity limits.

5Defined process to evaluate and improve movement and motion.

LevelShineAn effective, organized environment

1No visuals are in place. Work/break areas and machinery are dirty and disorganized.

2Visual display of data. Work/break areas and machinery are cleaned on a regularly scheduled basis.

3Visual controls are in place. Machines are cleaned daily. Customers/suppliers are identified and value defined.

4Real time metrics and visual management are in place. Preventative maintenance is implemented.

5Abnormal is immediately visible and triggers a planned response with root cause analysis and corrective action.

LevelStandardizeDevelop standards and stick to them

1No attempt is being made to document or improve current processes.

2Current process is known, but not documented.

3Current state is documented as Standard Work performed the same by all employees.

4Future state is documented. Implementation plan is actively worked. Area metrics are linked to OpEx metrics.

5Improvements are based on data and tracked for actual results.

LevelSustain5S is a way of life

1Minimal attention is spent on 5S.

25S is a scheduled event.

35S practices are evaluated on a regular basis.

4Documented methods (Red Book) have been put into place to ensure adherence to 5S.

5Employees continually seek improvement opportunities.

&L&12Area:&U .&C&"Arial,Bold Italic"&16 5S Level of Excellence Factory&R&12Date:&U &U.&U

Factory Audit

LevelSort Identify and eliminate what is not neededLevel of ExcellenceComments

1Necessary and unnecessary items are mixed together in the work area.12345



4Documented method has been established to maintain work area free of unnecessary items. Use of Red Book.

5Employees continually seeking improvement opportunities.

LevelSet in Order A place for everything and everything in its placeLevel of ExcellenceComments

1Tools, supplies and materials randomly located.12345


3Designated locations are marked to make organization more visible

(color coding, outlining, labeling, numbering, etc).

4Documented method has been established to recognize with visual sweep if items are out of place or exceed quantity limits. Use of Red Book.

5Vehicle developed to provide continual evaluation and process in place to implement improvements.

LevelShine An effective, organized, professional environmentLevel of ExcellenceComments

1No Visuals in place. Factory / work areas and machinery are dirty and disorganized.12345

2Some Visuals in place & Work / break areas are cleaned on a regularly scheduled basis.

3Visual controls in place as required & Work / break areas are cleaned daily.

4Visual controls practiced continually. Housekeeping tasks are practiced continually. Red Book

5General appearance of excellent visual controls. Area has developed a method of preventative cleaning and maintenance.( Stop the mess before it happens)

LevelStandardize Develop standards and stick to themLevel of ExcellenceComments

1No attempt is being made to document or improve current processes.12345

2Methods are being improved but changes haven't been documented.

3Information on process improvements and reliable methods are shared with employees.

4Changes are being incorporated and documented.(Past 5S sheets, Value Stream Implementation Plans, Process Improvement Sheets. OpEx Metrics are being tracked and demonstrate area improvement). Use of Red Book.

5Employees are continually seeking elimination of waste with all changes documented and information shared with all.

LevelSustain 5S is a way of lifeLevel of ExcellenceComments

1Minimal attention is spent on adhering to the 5 Ss.12345

2A recognizable effort has been made to adhere to the 5 Ss.

3Adherence to 5 S policy and procedures.

4Documented methods have been put into place to ensure Self-discipline. Use of Red Book

5General appearance of a confident understanding of and adherence to the 5S program.

AREA FOCAL'S NAME:___________________________________ TOTAL 5S LEVEL:_________


Office Audit


1Necessary and unnecessary items are mixed together in the office area. (Piles of paper work)12345

2Necessary and unnecessary items are separated, excess files, unused ref Matl, Boxes of files, Broken items are still present.

3All unnecessary items have been removed from the office area, files and drawers are organized.




1Office area shows no sign of organization. Items are randomly located.12345

2Designated location established for all items as required.

3Designated locations are marked to make organization more visible, in basket, WIP, Task board





1No Visuals in place. Office and computers are dirty and disorganized.12345

2Some Visuals in place. Office and personal work surfaces cleaned on a reg. scheduled basis.

3Visual controls in place as required. Office area cleaned daily.

4Visual controls practiced continually. Housekeeping tasks are practiced continually. Use of Red Book.

5Excellent visual controls. Office has professional appearance.





4Changes are being incorporated and documented.(Past 5S sheets, Value Stream Implementation Plans, Process Improvement Sheets. OpEx Metrics are being tracked and demonstrate area improvement). Use of the RED BOOK

5Employees are continually seeking elimination of waste with all changes

documented and information shared with all.





4

5General appearance of a confident understanding of and adherence to the 5S culture.


&L&12Area:________________.&C&"Arial,Bold Italic"&16 5S Level of Excellence Office&R&12Date:&U &U.&U

Group 5S Level

Team Member NameSort LevelSet in order LevelShine LevelStandardize levelSustain LevelOverall Rating by Team MemberOverall Team Rating

&C&"Arial,Bold"&24Group Name, 5S Level of Excellence

&LOP EX&C&"Arial,Bold"&12DATE:

5S IS A WAY OF LIFE Set In Order Levels of Achievement

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Group 5S Level




5S IS A WAY OF LIFE Shine Levels of Achievement

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4Documented methods have been put into place to ensure Self-discipline. Use of the Red Book.




Group 5S Level




5S IS A WAY OF LIFE Standardize Levels of Achievement

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Office Audit































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Group 5S Level




5S IS A WAY OF LIFE Sustain Levels of Achievement

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Group 5S Level




ProcedureObserve the itemsObserve the Output in the figureKeep the respective essential items near by hand.Make it with less utilization of timeMake sure the output is done correctly

Output

Time study & Lean Assessment using Torch Factory Application

Basic Steps in Time StudySelect the work/method/operation/process to be studiedObtain and record the details about the operations and the operator being studiedBreakdown the work into suitable elementsMeasure the time for each element and hence the time for the work cycleSimultaneously rate the operator performance.

Activities in Torch FactoryTake the lower part of the torch.Insert the batteries and the black ring.Place the upper part in the floor.Take the upper part and place the glass.Insert the bulb holder and put the bulb.Cover the bulb with the steel ring.Put the cover for the bulb and complete the upper part.Insert the upper part with the lower part .check for the working of the torch.

Time & Motion Study Using Plug Factory

ProcedureTaking lower capTaking black cord grip and placing in slot Taking screw 1 and putting in holeTake Screw DriverFixing screw 1Putting screw driver on the tableTaking Screw 2 and putting in holeTaking screw driver again Fixing screw 2Putting screw driver on the table againTaking blue pin and putting in slot

Talking brown pin(fuse Holder) and putting in slotTaking fuse holder and inserting in the slotTaking fuse and fixing with the fuse holdersTaking the top covers and placingTaking screw driver to fix the top coverScrewing the top coverPutting the screw driver on the tablePlacing the assembled 3 pin plug in the tray

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