Stability & Standardization

7 Types of Waste7 Types of Waste  Motion (Unnecessary movement)  Waiting  Transportation or conveyance  Storage (Excess inventory)  Defects  Over-processing or incorrect processing  Overproduction

Stability  Stability: Capability to produce consistent results over time  Instability: Result of variability in process  Sources:  Equipment breakdown  Equipment slowdown  Equipment performance variation  Defects  Demand fluctuations  Interruptions  Etc.

Indicators of InstabilityIndicators of Instability  High degree of variation in performance measures  Plan changes  No consistent pattern or method of work  Random WIP; Inconsistent or nonexistent flow  Island processes  Frequent use of the words usually, normally, typically, generally, most of the time, followed by except when  Statements such as, “We trust the operator to make decisions about how the work is done”

Objectives of StabilityObjectives of Stability  Basis for consistency  See “reality”  Remove random activity  Foundation for improvement spiral  Crucial for preparation of flow phase

Strategies in Stability PhaseStrategies in Stability Phase  Eliminate “big” waste  Consolidate waste  Improve operational availability  Eliminate or reduce variability

Eliminate “Big” WasteEliminate “Big” Waste  Standing in the circle  Standardized work (as an analysis tool)  5S

Consolidate Waste ActivitiesConsolidate Waste Activities  Make it visible  Provide focus

Improve Operational AvailabilityImprove Operational Availability  Quick changeover  TPM  In-cycle losses  During the work cycle  Excessive motion and equipment travel time  Small amount, high frequency  Poor yield  Out-of-cycle losses  Equipment not operational  Large amount, low frequency

Eliminate or Reduce Variability (Muri)Eliminate or Reduce Variability (Muri)  Two forms of variability:  Self-inflicted variability - that which you control  External variability -  Customers (primarily)  Suppliers  Product  Combine and isolate  Level daily (hourly) requirements

Primary Lean Tools in Stability PhasePrimary Lean Tools in Stability Phase  Genchi gembutsu – Go and see  Standing in the circle  Standardized work Standardized work  5S and Workplace organization 5S and Workplace organization  Preventive maintenance  Problem solving  Six Sigma Tools  Basic heijunka

Secondary Lean Tools in Stability Phase  Data collection and measurement  Story boards

Standardized Work in the Stability PhaseStandardized Work in the Stability Phase  Identify the basic work steps  Record the time for each step  Draw a picture of the work area and the operator’s flow within the area

5S and Workplace Organization5S and Workplace Organization  Purpose:  Eliminate waste of motion and searching for tools and material  Develop disciplined work habits

5S and Workplace Organization5S and Workplace Organization  Sort (Seiri): Clear out rarely used items by red tagging  Straighten or Set in order (Seiton): Organize and label a place for everything  Shine (Seiso): Clean it  Standardize (Seiketsu): Create procedures to maintain the first 3S’s  Sustain (Shitsuke): Use regular audits to stay disciplined

5 S5 S 16

What it looks like in the office:What it looks like in the office: 17

What it looks like in the shop:What it looks like in the shop: 18

Which one is Better?Which one is Better? 19

 Questions?

Assignment 2 5%Assignment 2 5%  5 S your bedroom  Show pictures of ‘before’ and ‘after’  Describe the changes you made and what types of wastes were improved  Due Monday