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Canadian Collision Industry Forum
Mississauga, Ontario
January 21, 2006
Process & Innovation Committee
Committee Members Ken Friesen, Concours Collision Tony Canade, Assured Automotive Bob Dubreuil, Akzo Nobel Paul McFarlane, The Boyd Group Mark Bonsor, Dupont Wayne Riley, Aviva Canada Neil Anderson, Anderson Consulting Tom Bissonnette, Parr Auto Body
PROCESS ENGINEERING Your Business Where Do I Start ?
Ken Friesen Process Mapping Tony Canade’ 7 Types waste Bob DuBreuil 5 ‘s
Admin Process
Total Days: 32 Steps 42 Value 13 Travel People 1478ft. Product 524ft. Time Total 156min. Non Value 128min. Value 28min.
Planning Process
Total Days: 12 Steps 54 Value 5 Travel People 4029ft. Product 524ft. Time Total 131min. Non Value 94min. Value 37min.
Production Total Days: 5.5 Steps 48 Value 11 Travel People 8173ft Product 1524ft Time Total 684min. Non Value 113min. Value 571min
Total Total Days: 19.5 - 32 Steps: 144 Value: 29 Travel People: 13,680ft 2.6 miles Product: 2,577ft .5mile Time Total: 971min. 16.2hrs. Non Value: 335min. 5.6hrs. Value: 636min 10.6hrs
Waste - Muda
“Muda” means Waste – specifically any human activity which absorbs resources but creates “no value” to the Customer (insurer, vehicle owner)
7 Types of Waste
Rework – product or admin. Overproduction –of goods
not needed by next step Inventories – goods waiting
to start or further processing
7 Types of Waste
People Movement – office/shop Product Movement –
office/shop Process Time – goods /admin. Waiting/Sleep Time
Based on Japanese words that begin with “S”.
5S philosophy focuses on: Work place organization Standard Operating
Procedures
What is 5 S?
Simplifies the work environment
Reduces waste Reduces “non-value” activity Improves quality efficiency Improves workplace safety
What is 5 S?
Sorting (Seiri) Set in Order (Seiton) Scrubbing Clean (Seiso) Standardizing (Seiketsu) Sustain (Shitsuke)
What is 5 S?
Why 5S? • Eliminate waste from
uncontrolled processes• Improve delivery consistency• Gain control of equipment,
material, and inventory• Improve quality• Improve safety• Improve consistency
# 1 – Sorting
Process to eliminate unnecessary items from the workplace
Tag and evaluate need Move occasional use items to
storage location Discard unneeded items (scrap
etc) Get rid of “J.I.C.” mentality
Systematic Sorting & Organization Eliminate space taken up by unneeded items-huge
toolboxes, benches, scrap parts Remove outdated papers and files Reduce cabinets, shelving, lockers that have no
current use Eliminate outdated posters, wall boards, metrics,
slogans, banners
# 2 - Set in Order
“A place for everything and everything in its
place” Equipment – shop and office Tools Cabinets and files Brooms and trash cans!!
Sort Visual Colour System
Work areas (mark on the floor) Aisle ways Equipment locations Storage locations
#3 - Scrubbing Clean
The cleaner the better Clean areas where red tagged items
were removed Remove dirt, oil, scrap, and garbage Look at lighting Clean on a daily basis Audit the cleaning process Improve equipment maintenance
Scrubbing Clean Clean aisles, walkways, floors,
machines, desks Assign cleaning responsibilities Create target areas: equipment,
floors, inventories Cleaning checklists Correct deficiencies Cleaning is a team effort Correct root cause of messy areas
# 4 - Standardize Standard Operating
Procedures Implement “SOPs” in all areas Involve staff in developing “SOPs”
Involve vendors Involve consultants Document all SOPS
Standardize
Step 1: PlanningWho does what and when
Step 2: AllocationAssign resources to tasks
Standardize Step 3: Act
Train all employees
Step 4: Implement
Step 5: Verify Ensure effectiveness
# 5 - Sustain Most difficult of the 5 S Employees tend to return to “comfort zone”
Need to monitor and influence until new culture becomes the “status quo”
Takes time!!
Benefits of 5S Increased efficiency Increased productivity Increased profitability Improved moraleA nicer place to work
Clean is Lean!
“THANK YOU FOR YOUR TIME!!”
Please join us in our Breakout Session this Afternoon!!