COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

APR

REPORT CHK APR

Q’ Production Team

Nov’09

7 Waste Elimination Plan

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

7 – Waste ( Overview )

Our Objective > Value Added = Maximum

Non Value Added = Minimum

Productivity Output

----------------Input

=Output

----------------Minimum Input

=Output

----------------Input + Waste

=

> Why to Identify and Eliminate Waste ?

Eliminate to Improve Productivity

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

7 – Waste ( Overview )

1

2

3

4

5

Waste from Over Production

Waste from Over Processing

Waste of Waiting Time

Waste of Motion

Waste of Transportation

7 Waste of Inventory

6 Waste from Defects

List by Toyota

( Found in Manufacturing )

9 Mis-used Resources

8 Untapped Resources

11 Waste of Communication

10 Waste of TalentRecently added wastes

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

7 Waste Elimination Plan

Type of Waste Description Reason Action Plan Target Remarks

1. MotionOperator motion does not add value

Working height, work distance and work area more.

Study work area and improve the condition

Dec’09 Height – Nov’09

2. Over Production

Excess Quantity.

No confidence in Process, Setup quality, Equipment and make use.

Identify line wise excess production and do line balancing

Jan’10Top 10 parts will be taken

3. Over Processing

Non value added

Operators not clear what exactly to be done.

Auto mode check, observing process identify

Mar’10Top 10 parts will be taken

4. Waiting Operator / Machine

No multi skill, no preparation of matl and tools

Line stop system and start up system improvement

Feb’10

Line stop & Top 10 tool clamping problem will be taken

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

7 Waste Elimination Plan

Type of Waste Description Reason Action Plan Target Remarks

5. Transport

Distance between two machines / locations

Improper process flow, improper layout.

Layout change and elimination of temp storage.

Dec’09

Top 5 Machines will be taken

6. Defect Rework / rejection

Process itself produce defective which to be be reworked / scrapped

PPM Level study and Q chart use Nov’09

Top 5 parts will be taken

7. Inventory Holding of stock

Result of over production, Machine failures and defectives.

My machine concept & SAP system usage

Apr’10

Top 10 high inventory parts will be taken

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

Motion – 1 ( Man movement )

NO TASK

PLAN

STATUS TARGETCHARGE(TEAM)ACTIVITY

EFFECTAMOUNT

1 Working height standardisation

Studying existing work height and altering the area to standard

5,000 Data collected 15-11-09 Q.P.

2 Work distance and Arm movement standardsiation

Analysing all work area for standard distance and crate keeping location and operator turn position

20,000 To be started 15.12.09 Q.P.

3 Champions moving from the area .

Making system for calling support team for their requirement. ( Line stop alarm system )

2,50,000To be

planned10.01.10 Maint

COMPETE TO WIN 2009

Team Slogan – Think SSS ( Simple , Straight & Short )

7 Waste – Action Plan

Major activity Detail Action P/

A

Date ( Nov’09)Remarks

oct 1 2 3 4 5 6 7 8 9 10 11 12 13 1415-

20

Working Height system

1. Training to staff regarding working height

P

A

2. Making standard format for data collection

P

A

3. Collection of dataP

A

4. Compiling and analysis

P

A

5. Making implementation plan

P

A

6. Modification of working height

P

A

7. Making standard to all lines

P

A