Lean Kaizen
Lean Kaizen
Lean Kaizen
Project tEAM
Project Sponsors: Mian Atiq Mian Nadeem Team Leader: Ishtiaq (Folding) Consultant: Qadeer Bhatti
Team Members: Saleem (PPC) Khalil (Logistics) Imran (Quality) Razwan (IT) Afzal (Electrical) Usman (HR) Asad (Lab) Shahab (Mech)
Objectives
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Segregation of Products according to acceptable quality. On the spot defect removal. Accurately measurement and recording of products. Packing to customers required parameters piece length, packaging material etc. Accurately Marking and numbering. Convenient and safe storage, access and movement of goods. Accurate, efficient and safe loading for dispatching of goods. Preparation, issuance and controlling products for rework. To facilitate internal and external quality audit. Selection of efficient and effective men, materials, machines, and methods. Maintenance of machines and facilities for overall effectiveness. Efficient and safe Packaging material receiving, storage and issuance. To create a safer, more productive and organized workplace.
Kaizen newspaper
Kaizen Newspaper
Project: ________Folding____________
Complete Under process Did Not Work Not Started
No Action Required
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Color Coding Trollies Estimated Time for Reprocess Customer Complaint relevant to Folding of one year. Safety Guard installation on Folding Machine Last Six month data of all happened accident in folding Six month data of all work orders relevant to Electrical Six month data of all work orders relevant to Mechanical To install Andon Board on all machines To install signaling system for Quality Section. To fix the loading trollies problem To standardized weight for Trollies To convert hard copies data in to soft copies. Work Flow Diagram of Folding Folding Machines Layout
Person Responsible
Shahab Saleem Ishtiaq Shahab Usman Afzal Shahab Afzal Ishtiaq Shahab Ishtiaq+Usman Rizwan Ishtiaq Ishtiaq
Status
Due Date
31/10/2012 31/10/2012 04/10/2012 03/11/2012 13/10/2012 03/10/2012 13/10/2012 10/11/2012 10/11/2012
Comments
PPC/Marketing
Customer (Export/Commercial)
Folding Manager
Receiving
Inspection
Folding
Segregation
Rolling
Packing
QC
Dispatch
I
12762
I
24295
I
0
I
4000
I
4000
I
6199
I
724084
VA
4h, 45m
10 m
1h, 50m
15 m
30 m
20 m
NVA
1h, 55m
15 m
8d
Improvement Opportunity
Objectives 1. Segregation of Products according to acceptable quality. 2. On the spot defect removal.
Segregation of products
Added two extra inspection tables. Took color blindness test of 81 people from printing, Finishing, Lab, Design Studio, Quality and Folding to check the checkers/operators ability to distinguish between different colors. 10 people out of 81 failed the color blindness test. Took 4 point system test for quality inspection of all the checkers and operators from grey to Folding. Delivered 4 point system training to all the operators and the checkers to fill their skill gap.
Accurately measurement
Counter meters are now being calibrated one a month. Wheels made of Tufnol material will be used instead of plastic which are long lasting. Work is being carried out to upgrade the counting meters using electric proximity sensor with mechanical fitting.
Accurate measurements
A program is in place to regularly calibrate the weighing scales. Due to unbalanced movement of weighing scales from one place to another, scale load cell stop working properly and the scale gets out of calibration. A new dollie with locked wheels has been developed in house. Scale movement with dollie will eliminate the problem of malfunction and also save one person during scale movement.
Accurate measurements
Before
After
Objectives: 4. Packing to customers required parameters piece length, packaging material etc. 5. Accurately Marking and numbering.
Objectives: 6. Convenient and safe storage, access and movement of goods. 7. Accurate, efficient and safe loading for dispatching of goods.
6 Feet
Audit Facilitation
A comprehensive checklist has been developed. There are 41 questions in the checklist. The checklist contains all the knowledge areas e.g. social policy, quality policy, health and safety policy and other benefits provided to the employees. Checklist is currently under final review by the management and will be operational once approved.
Objectives: 10. Selection of efficient and effective men, materials, machines, and methods. 11. Maintenance of machines and facilities for overall effectiveness.
Effective Methods
Before After
Effective Methods
Before After
Effective Methods
Before After
Centre
270/950 800/1090 820/1040 950/1020 780/1070 760/1095 740/1120 470/990 450/1050 450/1040 350/1050 320/1090 400/1010 350/1070 320/1070 300/1020 530/900 200/710 400/1020 280/920 250/1070 510/780 300/530 460/790 610/1100
Right
Before/ After
318/1040 880/1080 780/1090 1160/1070 680/1090 740/1065 760/1090 470/1030 480/1120 550/1000 350/1030 320/1040 370/1040 360/1090 335/1090 330/1090 410/720 300/750 350/950 300/870 340/800 420/720 280/400 430/730 580/1040
Effective Methods
Responsibility Assignment Matrix (RACI) for Commercial Party Fabric Processing
Department Activity/Process Order Taking Planning Quality Grey Bleaching Dyeing Design Studio Printing Finishing Lab Folding Logistics sub-process Print Dye White Marketing A/R A/R A/R C I I I C C C C C PPC C C C A/R I C C C C C C C C C Grey I I I C I A/R C Quality I I I C A/R C C C I C C C C C Bleaching I I I C I I A/R C C C C I Design Studio I Printing I I C I I C I I C C A/R C C I C I I C A/R Dyeing Finishing I I I C I I C C C A/R C I Lab I I I C I C C C C C A/R C C Folding I I I C I I I I I C C A/R C
A/R C
C C I
R = Responsible: Those who do the work to achieve the task. There is typically one role with a participation type of Responsible, although others can also assist in the work required. A = Accountable: The one ultomately answerable for the correct and thorough completion of the deliverables. In other words, an Accountable MUST approve on work that Responsible p C = Consult: Those whose opinions are required with two way communication. I = Informed: Those who are kept up-to-date on progress with only one way communication.
Objective: 12. Efficient and safe Packaging material receiving, storage and issuance.
Safe packaging material All the storage racks have been repaired for safe packaging material storage. A new rack has been made for all kinds of polythene bags, Twin jute etc. More frequently used material and supplies have been placed closer to the point of use. All the racks have been labeled with the material name and size etc.
packaging material
Before
After
Before 5S
1s - sort
2s - Set in order
4s - Standardize
4s - Standardize
5s - Sustain
Regular 5S inspection by supervisors and the Folding manager. Celebration of monthly 5S day. Weekly meetings of all Folding employees and the manager to discuss different ways to create a culture of continuous improvement. 5S training for all new starters. Regular audit by compliance officer.
6s - Safety
Before After
6s - Safety
Before After
6s - Safety
Before After
Visual management
Continuous improvement
Be better today than you were yesterday and better tomorrow than you are today.