Ortiz Kaizen Assembly

Designing, Constructing, and Managing a Lean Assembly Line
Erscheinungsjahr 2006
ISBN: 978-1-4200-0660-5
Verlag: Taylor & Francis
Format: PDF
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 264 Seiten

It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation.

Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them.

Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.

Zielgruppe

Assembly manufacturers, industrial and manufacturing engineers, engineering managers, plant managers, graduate students in engineering, and industrial engineering professors.

Autoren/Hrsg.

Ortiz, Chris A.

Fachgebiete

• Wirtschaftswissenschaften Volkswirtschaftslehre Volkswirtschaftslehre Allgemein Industrielle Organisation

Inhaltsverzeichnis

1
Commitment to Change

Chapter Summary
2
The Company Kaizen Program

Kaizen
Kaizen Events

Kaizen Program
Create and Communicate the Vision

Establish the Kaizen Champion
Communication Boards and Newsletters
The Kaizen Governing Committee

Kaizen Champion

Plant Manager

Production Manager
Engineering Manager
Materials Manager
Quality Manager
Facilities/Safety Manager

Human Resources Manager
Kaizen Team Selection
Team Leader

Team Members5
Process Engineer

Quality Engineer

Facilities/Maintenance Personnel

Materials Handler

Line Operators
Management

Kaizen Event Tracking System

Kaizen Tracking Worksheet

Kaizen Event
Team Leader
Team Members

Date and Length
Strategic Purpose

Anticipated Results
Preplanning
Estimated Cost
Event Spending

Actual Results
Action Items
Due Dates for Action Items
Responsible

Status
Kaizen Monthly Meetings and the Kaizen Event Supply Box
Kaizen Monthly Meeting
Discussion of Open Action Items: 15 Minutes
Discussion of the Last Event's Results: 20 Minutes
Planning Upcoming Events: 30 Minutes
Kaizen Event Supply Box
Chapter Summary
3
The Basics

The Seven Wastes, 5S, and Standard Work

The Seven Wastes

Overproduction

Wait Time
Transportation
Overprocessing
Inventory

Motion
Defects/Rejects

The Eighth Waste
5S

Sort
Straighten.
Scrub/Shine

Standardize

Sustain
Standard Work

Chapter Summary
4
The Strategic Purpose
Business Metrics

Productivity

Floor Space Reduction

Work Station Reduction
Travel Distance Reduction

Quality
Work in Process (WIP) and Inventory Reduction
Effective Hours

Product Volume
Takt Time and Cycle Time

Takt Time
Cycle Time
Visual Management
Production Control Boards
Weekly 5S Board

Daily Quality Data
Safety Board
Daily Productivity Board
Takt Monitors
Chapter Summary
Electric Bike - Kaizen Event Preparation
5
Four Weeks to Go

Select the Area and the Kaizen Team Leader
Order Supplies and Equipment
Antifatigue Mats

Lift Tables
Tool Balancers or Retractors

Metal Tubing

Floor Tape and Laminating Material

Labels
Parts Racks
Plastic Part Bins

Workstation and Tower Lights
Miscellaneous Preparation
Time and Motion Studies
Time and Motion Study Rules

Use a Stopwatch
Use a Time Study Collection Sheet
Document the Tasks and Elements
Capture Every Piece of Work Content

Involve the Operator

Conduct the Time Studies

Capture at Least Eight Samples

Time All Options
Remove the Highest and Lowest Times and Take
an Average
Time to Begin the Kaizen Event

Chapter Summary
6
Waste Analysis

Current State

Cycle Time versus Takt Time
Equipment Constraints
Changeover Time
Material Optimization

Waste

Waste Observation of the Electric Bike Assembly

Main Assembly Line
Miscellaneous Value-Added and Nonvalue-Added
Work

Future State

Chapter Summary
7
Two Weeks to Go

Select the Kaizen Team Members
Get an Update on Supplies and Equipment

Miscellaneous Preparation
Line Balancing

Resource Requirements
Eliminate Nonvalue-Added Work
Balance by Time
Balance by Work Content

Balance by Material

Chapter Summary.

8
One Week to Go

Gather Current State Statistics

Meet with the Team Members

Miscellaneous Preparations.

Standard Work Sheets

Main Assembly
Headlight Assembly

Chapter Summary
The Kaizen Event - The Electric Bike Line
9
Day One

Kickoff Meeting

Ground Rules
Be on Time

No Cell Phones or Pagers

100% Dedication of the Team
Eat Lunch as a Team
Stay Positive

Make Decisions and Stay on Schedule

Let's Get to Work

Red Tag Team
Review of the Standard Work Sheets
Lunch Break

Midday Meeting
Completing the Red Tag Event
End of Day Meeting

Chapter Summary
10
Day Two and Day Three Line Design

Midday Meeting
Assembly Line Construction
Maintenance and Machine Shop Projects

Tool and Part Presentation

Tools57
Tool Balancers

Tool Stands

Shadow Boards
Parts
The Two-Bin System

Part Use in Containers

Large Part Use Not in Containers
Subassemblies

Day Three

Subassembly Work Cell
Main Assembly Line
Chapter Summary
11
Day Four

Workstation Signs and Parts Rack Signs
Floor Taping and Designations
Two-Bin System Labels

Color Labels.3
Two-Bin System Assignments

Subassembly Build Levels

Installing Shadow Boards and Tower Lights

Production Control Boards
Takt Monitor
Chapter Summary
12
The Final Day

5S Audit Sheets
5S Tracking Sheet

Work Instructions
Quality at the Source

Employee Cross-Functional Matrix
Rate Cards

Standard Work for Three Different Rates

Line and Operator Placement Map
Standard Workbook

Line Tour
Chapter Summary
13
Training and Accountability

Training

Single Piece Flow (Push vs. Pull)

Flexing

Effective Hours

Tower Light Use
Two-Bin System

Build Levels
New Employee Training

Product Overview

Lean Basics
Incentive and Pay for Skill
Mock Line Training

Accountability
Daily Guidelines

Ongoing Guidelines

Chapter Summary4
14
Moving Forward
More Kaizen
Kaizen Event Ideas

The Second Pass Kaizen Event

Inventory Reduction Event

Line Removal Event
5S Event

Line Design Event
Material Handling Event

Mistakeproofing.

Product Design
Eliminating Picking Errors
Use of Fixtures or Jigs
Visual Indicators

Ergonomic Evaluations

Chapter Summary
15
Coin Dispenser Manufacturer Success Story

A10 Line Kaizen Event, Kaizen Team

Day One

Day Two

Day Three
Day Four

Day Five Closeout

Six Months Later
Final Thoughts
Glossary

Index