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Lean assessment – Current State
The Lean journey starts with assessing the current state of the plant. This assessment should include the following operational standards
Planning Cycle to Meet Plant Objectives
Standardized Work for Leaders
Standardized Work for Operators
Monitor Progress & Adjust using Standardized and Structured Methods
Establish Mentor-Mentee Relationship at All Levels
Value Stream Alignment & Structure
Leaders as Teachers
5-S / Visual Management
Flexible Operations
Error Proofing / Poka Yokes
Quick Change Over
Total Productive Maintenance
Synchronous Material Flow
Level Production
Lean – Future State
Based on the lean assessment, value stream mapping of the current state of the product line as a whole and current state map to the individual line will be done and based on the outcome of the current state, projects will be allocated to the teams.
If it is a machine availability issues then that particular machine will be referred to Tpm team as a Tpm project.
If it is a quality related issue then the issue will be referred to Quality circle or six sigma candidates based on the severity of the quality issue.
If it is flow related issue then the product line will be referred to SMF (Synchronized material flow) team. In SMF the team will work on material flow with 2bin system or kanban system
If it is a issue with the working environment then the Visual factory team will work on 5S , visual aids , operator work instructions etc.
Initially model line should be identified and the lean team should start working on the model lines. For each and every step of the initiative the employees should be involved. This will have a very good impact by the way of giving good inputs for system design and also create a ownership among the employees.
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