Look at these two pictures.
picture on the left was taken "before" any changes were made the one on the right was taken
"after" the shop was re-organized.
Even though the
area seemed organized and the rolls were all kept on racks, it was easy to
select the incorrect roller and start to install it on the printing machine. It
was also possible to install the wrong toothed gear on a roll and not notice
until it was too late. Before the change the employees at this company could
and sometimes did install the wrong mix of roller and gear for a particular
print job. This when discovered meant breaking down the machine to fix the error
and of course it meant lost time and materials.
As part of a
Kaizen event TEiM helped the workers in the area implemented a mistake proof
color coded systems to make sure the right roller and gear combination was
Controls are the foundation of a Lean organization, whether it be color coding
of a machine or paperwork and files in an office. It al goes to eliminating the
potential to make mistakes. Having good visual control also enables the
supervisors and managers to detect if something is not right in an area which
may cause delays to production.
The mantra for
good visual controls should be
“ A place for everything and everything in its place” TEiM can help you establish top class mistake
proof Visual controls at your location.
You can usually
gauge any company's attitude towards quality by simply taking a 10 minutes tour
of their facility and assessing their commitment to a workplace organization
plan. To prove this point do what Teim calls "The 30 second challenge."
Here are the simple steps:
Go to your workplace and get ready
to start doing your job.
How much time does it take to find the first item you
Did you find the first item in 30 seconds or less?
Now try it with the next 2
or 3 items.
If you can't
find what you need in 30 seconds or less, your are wasting valuable time
throughout the day, week, month and year searching for parts or equipment. So,
now its time to think about
what it's really costing you to make your products, because while a person is
searching for items, they cannot produce anything.
You can calculate the impact of wasted time on your business. If your employees
are wasting 30 minutes per day doing other activities (e.g. looking for tools,
equipment, etc) other than doing their actual job, what is it costing your
Average work year has 250 days
per year. 30 minutes (or 0.5 hours) per day =
250 / 0.5 = 125 hours per
If an employee
is earning $15 per hour, the cost is: 125 hours x $15
= $1875 per employee per year.
So, you can do this calculation
for the total number of employees in your organization:
= $18,750 per year
= $93,750 per year
= $187,500 per year
As you can see from this
example its really important to know what portion of the workday is taken up
doing non-value added activities. If you don't know how much time is lost, its costing
someone money and guess who pays for it in the finished product, your customers. Companies will spend thousands of dollars trying to track direct
labor costs but still have no idea of how much time is wasted throughout the process.
Any company trying to implement
lean will not succeed without creating a clean and orderly workplace. The motto
for workplace organization is "A place for everything and everything in it's
place." If it's not in its proper place, then someone has to take time away from their
job to go find it and that's just simply waste.
To achieve a better level of workplace organization you
will use two Lean techniques: