Stability & Standardization

7 Types of Waste Motion (Unnecessary movement)

Waiting

Transportation or conveyance

Storage (Excess inventory)

Defects

Over-processing or incorrect processing

Overproduction

Stability Stability: Capability to produce consistent

results over time

Instability: Result of variability in process Sources:

Equipment breakdown Equipment slowdown Equipment performance variation Defects Demand fluctuations Interruptions Etc.

Indicators of Instability High degree of variation in performance measures

Plan changes

No consistent pattern or method of work

Random WIP; Inconsistent or nonexistent flow

Island processes

Frequent use of the words usually, normally, typically, generally, most of the time, followed by except when

Statements such as, “We trust the operator to make decisions about how the work is done”

Objectives of Stability Basis for consistency

See “reality” Remove random activity

Foundation for improvement spiral

Crucial for preparation of flow phase

Strategies in Stability Phase Eliminate “big” waste

Consolidate waste

Improve operational availability

Eliminate or reduce variability

Eliminate “Big” Waste Standing in the circle

Standardized work (as an analysis tool)

5S

Consolidate Waste Activities Make it visible

Provide focus

Improve Operational Availability Quick changeover

TPM

In-cycle losses During the work cycle Excessive motion and equipment travel time Small amount, high frequency Poor yield

Out-of-cycle losses Equipment not operational Large amount, low frequency

Eliminate or Reduce Variability (Muri)

Two forms of variability: Self-inflicted variability - that which you control External variability -

Customers (primarily) Suppliers Product

Combine and isolate

Level daily (hourly) requirements

Primary Lean Tools in Stability Phase

Genchi gembutsu – Go and see Standing in the circle

Standardized work

5S and Workplace organization

Preventive maintenance

Problem solving Six Sigma Tools

Basic heijunka

Secondary Lean Tools in Stability Phase

Data collection and measurement

Story boards

Standardized Work in the Stability Phase

Identify the basic work steps

Record the time for each step

Draw a picture of the work area and the operator’s flow within the area

5S and Workplace Organization

Purpose: Eliminate waste of motion and searching for

tools and material Develop disciplined work habits

5S and Workplace Organization

Sort (Seiri): Clear out rarely used items by red tagging

Straighten or Set in order (Seiton): Organize and label a place for everything

Shine (Seiso): Clean it

Standardize (Seiketsu): Create procedures to maintain the first 3S’s

Sustain (Shitsuke): Use regular audits to stay disciplined

16

5 S

5S - Workplace Organization (Tools)

Before

Tool Display in Transition

Final Tool Display with Shadows

Final – Consolidated Tool Box

Individual Tool Box

6SA-042a

5S - Workplace Organization (Tools)

Before

Tool Display in Transition

Final Tool Display with Shadows

Final – Consolidated Tool Box

Individual Tool Box

6SA-042a

Before 5S After 5S

17

What it looks like in the office:

BEFORE AFTER

18

What it looks like in the shop:

19

Which one is Better?

Make Standards Visual

Questions?

Assignment 2 5%

5 S your bedroom

Show pictures of ‘before’ and ‘after’

Describe the changes you made and what types of wastes were improved

Due Monday