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.
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
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