20 keys
TRANSCRIPT
Source: Iwao Kobayashi
20 Keys to Workplace Improvement
• Key 1: Cleaning and Organizing• Key 2: Rationalizing the System/MBOs• Key 3: Improvement Team Activities• Key 4: Reducing Inventory (Shortening Lead Times)• Key 5: Quick Changeover Technology• Key 6: Manufacturing Value Analysis (Methods Improvement)• Key 7: Zero Monitor Manufacturing• Key 8: Coupled Manufacturing• Key 9: Maintaining Equipment• Key 10: Time Control and Commitment
Iwao Kobayashi, Productivity Press
20 Keys to Workplace Improvement
• Key 11: Quality Assurance System• Key 12: Developing Your Suppliers• Key 13: Eliminating Waste (Treasure Map)• Key 14: Empowering Workers to Make Improvements• Key 15: Skill Versatility and Cross Training• Key 16: Production Scheduling• Key 17: Efficiency Control• Key 18: Using Information Systems• Key 19: Conserving Energy and Materials• Key 20: Leading Technology and Site Technology
Key 1: Clean and Organize
Level 1• Cigarette butts, scraps of paper, and tools are scattered about
Level 2• Clutters and piles of dirt lie against the walls• Passageways are not cleared• Unused items lean against walls• Unused tools or equipment lie around
Level 3• Walkways are clear and the factory is clean, but the storage areas are disorganized• Cabinets are locked and contents mixed together
Level 4• Machinery and equipment are clean
Kobayashi: 271-2
Key 1: Continued
Level 4 (continued)• Storage areas are clearly distinguished, and show parallel lines and right angles• Cabinets are unlocked
Level 5• Everyone cleans regularly• The work area is immaculate and tools are laid out squarely
Shingo, SMED; Kobayashi: 276
Key 5: Quick Changeover Technology
Level 1• Current operating belief is that lot sizes should be large enough to
reduce the number of changeoversLevel 2• Some employees have received quick changeover training• Setup time on all bottleneck equipment has been reduced by 90%Level 3• All manufacturing employees received quick changeover training• Setup time on all processing equipment has been reduced by 90%Level 4• Setup time is reduced to under 10 minutes on all equipmentLevel 5• Changeover time is less than time required to produce 1 cycle (part)