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Experience
Structure of Presentation
1.0 Purpose of 5S implementation
2.0 Unique aspects of 5S
2.1 See-through Layout
2.2 Identified location
2.3 Material at eye level
2.4 Improved visibility
2.5 Material handling system
2.6 Lean Flow
2.7 Improved environment for 5S
3.0 Sustaining of 5S
3.1 Daily work management
3.2 My machine – My line campaign
3.3 Operator training
3.4 TPM Implementation
3.5 Fixed point photography
4.0 Results
1.0 Purpose of 5S implementation
Valve position
2.4 Improved visibility - Continued
Follower position
Follower in Top position Follower in Bottom position
Top
Bottom
2.5 Material Handling system
All material on wheels
• No fork lift in side the shop floor
• No pallets
• Trolley design
• Crates with identification
• Blue – In-house machining
• Yellow – Casting
• Grey - Supplier parts
2.6 Lean Flow
Monthly/Weekly
Month/weekly/daily plan Fax
Daily
Production Marketing
Control Monthly schedule Customer
Supplier
Supplier SCL-Foundry
Da
Takt time
ily
Introduce electronic trigger
Or
de
4X Card between SCL and
60 Sec.
r
Milk run Daily Foundry
Demand/month
Heijunka card 25500 1X daily
Deburr removed
1020 nos /day
UB m/c
Fixed loading
OX OX
1 pattern
C/T=85s Shipping
FIFO Leak check FIFO Plating FIFO
Ultrasonic Assembly
Inspection CO=900 & deburr 2(shared) Cleaning FIFO Packing
stores Uptime=85.4% 10 1(shared)
I I 1 1 I
2 shifts I I
72 I 60
125
72 128 C/T=14s 54 C/T=60s C/T=240s
C/T=45s C/T=300s CO=0 CO=0
LB m/c CO=0
CO=0 CO=0
Uptime=100% Uptime=95% Uptime=100%
Uptime=100% Uptime=100%
C/T=300s 1 2 shifts 2 shifts 2 shifts
2 shifts 2 shifts
CO=0
Uptime=100% C/T=87s Operator rebalance
Auto unload In assy area
2 shifts CO=900
Uptime=85% Operator rebalance Value added Time 9929s
2 shifts In machining area Process Ratio = = 24.6%
Production lead time 40223s
Date - 20.09.2004
Generate
Schedule MRP MRP MRP
Resource planning
Produce
Machine Assembly
shop
Produce Produce
I
kanban WIP
Transfer
2.6.2 Spiderman replenishment
• Paced withdrawal of finished goods
• Material feeding based on Pull
Pitch 2 hrs
SWH Machine shop Assembly shop
Spiderman 1
Spiderman 2
Spiderman 3
Spiderman 4
`
Stores
2.7 Improved Environment for 5S
2.7.1 Environmental Parameters :
Target
Sl no Environmental Parameter Std
Phase 1 Phase 2
3 Lighting Lux Level: 300 - 500 Lux Level: 300 - 500 Lux Level: 300 - 500
v Dust level
monitoring using Achieved
Air borne hand ISO CLASS 9 ISO CLASS 8
2 Dust hand held 5 Micron particle 7000/ cu. ft 5 Micron particle 700/ cu. ft
particle counter
inside the
assembly room
v Uniform Achieved
3 Lighting distribution of Lux Level Achieved: 380 Lux Level Planned: 450
lighting in work
area
Maintaining at
4 Temperature Ambient– 2’ C
2.7.3 Noise level Mapping :
NOISE LEVEL MAPPING- AFTER Measured on 03/06/2005
83 dB 82 dB
84 dB
82 85 dB
79 dB 83 dB
65 dB 75 dB
76 dB
80 dB 81 dB
83 dB 81 dB
85 dB
83 dB 83 dB 76 dB < 80 dB
84 dB 85 dB 84 dB 81- 85 dB
> 85 dB
3.0 Sustaining 5S
3.1 Daily work management
• Sustaining through daily,weekly,monthly,half yearly & yearly checks
Kaizen
Portable compressor to build air for Booster provided to build air for
testing Easy to clean
testing
Easy to maintain
Difficult to clean
Space productivity improved
3.4 TPM Implementation :
3.4.1 Fugai – Operator wise monitoring
30 Plan
26
Nos of Fugai s
19 19 20
20 17 16 18
13
13
12
10
10 7 7
4 4 5
3
2
0
n
n
thy
iel
al
an
sa
sa
sm
an
ur
es
va
va
am
ra
ug
ur
ini
Pa
nth
Sr
thy
ur
am
Sa
Se
dr
un
So
Employees
3.4 TPM Implementation - Continued
3.4.2 Kaizen
2400
Plan
2000 1829 1859 1894
1735 1765
1600
No of Kaizens
1200
800
400
200
•153 / 265 machines are in Step 3 153
150
112
100
50
20
No. of machines
071401 061204
15 O71602
10 071701
0
J J A S O N
2005
3.4 TPM Implementation - Continued
40 38 38 38 38.5 41
Number of suggestions per person per year
Plan
30
26
20 17
Better
10 6
2
0
97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06
2. Employee morale improvement – Quality control circle
(QCC) projects
• 100% participation in QCC by all the employees for the past five
years
• Number of projects per circle per year has increased by 60% in
the past eight years
Plan
4 4
3.5
Number of projects per circle
1.5
1
Better
0.5
0
97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06
3. Employee morale improvement –
Safe working environment
Am happy with my
job(88%) 93%
Will recommend as a
good place to work(87%)
US manufacturing averages 88
US manufacturing best seen 92
GWA score is the best
worldwide India manufacturing average 85
India manufacturing best seen 89
ABC division 93