PRODUCTION EFFICIENCIES This isn’t your father’s production system!
WHAT’S IN YOUR DIRECT CONTROL? • How many units you sell? • How much you make off of each unit?
All we are doing is looking at the time line from the moment the customer gives us an order to the point when we collect the cash. And we are reducing that time line by removing the non-value-added wastes. -Taiichi Ohno
WHAT’S WASTE?? ANYTHINGYOUR CUSTOMER IS NOT WILLING TOPAY EXTRA FOR!
CORRECTION MOTION Repair, Rework Scrap, Labor, R & A WAITING Bending, lifting, turning, stretching, or reaching more than is absolutely needed. Cannot take away from value-added part of job Employee waits for tools, machine, materials, supervisor, maint., etc. Machine waits for… Inventory waits for… Waste EXCESS PROCESS OVER PRODUCTION Producing more than the customer requires, before the customer requires it Poor design of parts, poor maintenance of equipment, poor training/instructions and reworking parts INVENTORY CONVEYANCE Excessive raw materials, WIP finished goods, excessive supplies, requires extra space handling, paperwork Double or triple handling, long distance moving of materials and tools 8 WASTES + 1 UNDER UTILIZED PEOPLE Not allowing or challenging individuals and teams to use their creativity to solve everyday problems
The most dangerous kind of waste is the waste we do not recognize. -Shigeo Shingo
WHY DO WE FAIL TO RECOGNIZE WASTE? • Too “Busy” • Not Easily Identified • Working in the Short-Term • Don’t Ask the Right People • Fail to “Gemba” • “It Ain’t broke” • “Good is the Enemy of Great” -Jim Collins
HOW CAN WE START? • CREATE STANDARDS • AUDIT THE STANDARD
Best repeatable method agreed upon by everyone Defines “when” and “what order” Focused on human movements Should have one for every process that is repeated And……. STANDARD WORK
AUDITING You’ll Be Glad You Did It!!
“Whys” of Auditing • Is The Work Being Done Correctly • Is The Documentation Correct • Encourage Continuous Improvement
JASPER Presents BEAUTY SHOP
BEAUTY SHOP • Rules of Beauty Shop • All steps must be followed according to Standard Work. • Only operators may access tools from tool crib. • Any tool borrowed must be returned before moving on to next step. • 5 Minute cycle time • Auditors should insure SW is followed and look for areas of improvement.
BEAUTY SHOP THOUGHTS OR QUESTIONS
BEAUTY SHOP Guidelines for improvement • All steps must remain on SW, order can change • Sort, Set in order, Shine, Standardize, Sustain • Consider best utilization of people • Cycle time remains 5 minutes
DOES THIS STUFF REALLY WORK? • 43% IMPROVEMENT IN HPU • 56% IMPROVEMENT IN 0-90 DAY WARRANTIES • 46% REDUCTION IN WIP • 52% IMPROVEMENT IN PRODUCT THROUGHPUT TIME • IMPROVED CI’S PER ASSOCIATE FROM 1.3 TO 18.4 PER YEAR • ABLE TO OPEN OUR FIRST “DOJO”