LEAN : FOCUS ON PRODUCTS

CAUSE OF INSTABILITY

IMPROVE PRODUCTIVITY

POOR DELIVERY TO CUSTOMER

EMPLOYEES

OPERATOR

MAN

No Training

Improve Operator Efficiency

No training

Poor Relation with Supervisor

Reduce movement of Operator

Heavy absenteeism

No confidence in Management

Eliminate Over Time

Lack of commitment

Lack of commitment

Insufficient skill level

MACHINERY

PROCESS

MACHINE

Old & Frequent break down

Reduce Cycle time

Old & Frequent break down

No capability

Reduce Setup time

No capability

Improper Maintenance

Reduce movement of materials

Improper Maintenance

No proper tools

Improve throughput / Output

No proper tools

PROCESS

MACHINERY & EQUIPMENT

METHOD

Improper Process

Eliminate downtime

Improper Process

High loading / Unloading time

Eliminate rework / rejection

High loading / Unloading time

No Balanced cycle time

Balance the line-(Work to takt time)

No Balanced cycle time

Too much man movement

Improve process capacity

Too much man movement

MATERIALS

WORKPLACE

MATERIALS

Non availability of time

Introduce single piece flow

Non availability of time

Unwanted large inventory

Avoid Excess production

Unwanted large inventory

Poor Quality

Poor Quality

Poor Supplier relation ship

Poor Supplier relation ship

MANAGEMENT
False commitment
Poor workplace organisation
Poor communication
Poor Planning

REWORK / REJECTION
MACHINE
Insufficient machine capacity
Improper machine setup
OPERATOR
Insufficient Training
Over Burden
Improper handling
PROCESS
Unclear process
MATERIALS
Defective material
TOOLS
Work out tools

MANAGEMENT CONTROL SYSTEM - UPPER CONVEYORS

TASK
1 Production Logbooks & Daily Production Report
2 Section wise White Board
3 Technical Showboards (Tamil) In stage inspetion
4 Operater Showboards (Tamil) Article wise
5 Stage-wise Inspection Logbook
6 Component Replacement
7 Final Inspection Logbook and Report
8 Break down slip & Maintenance data base
9 Workers Training calender
10 Compliance % Non Compliance

STATUS
A
C1

A
C2

B
C1

B
C2

B
C3

B
C4

B
C5

B
C6

F
C1

F
C2

G
C1

G
C2

M1
C1

M1
C2

M1
C3

M2
C1

M2
C2

M2
C3

GSK2

GSK2

GSK3

GSK3

C1

C2

C1

C2