Download - Implementation pics
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All the employees are involved in taking Kaizen Shapath
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Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Employees
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Director to Doorman - all are equally involved in doing Kaizen at GEMBA
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Preventive Maintenance through Visual Management
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Visual Management – Pigments stored in all the containers are visible and known
Transparent containers
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Through color coding, it is easy to know which tools and components belong to which dept.
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PEEP (Place For Everything and Everything in its Place) When the person has taken a tool, he will place a token at the place that will let others know where the tool is now and with whom
Token
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Standard WIP
Output
Input
1. Frontline workers are cleaning their workstations to keep their workplace dust-free2. Standard WIP has been kept near every workstation3. All the components have been color coded according to their functionality and stored at the point of use (POU)
Color coding
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This is an example of One Piece Flow AssemblyEach and every component needed is available at a hands distance of the worker
Plan vs. Actual production
display board
Light indicator to give signal
Packaging
Material at hands
distance
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Learning Center - where all kinds of tools are kept to train the employees
Worn out/Waste tools are kept in
one line
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SMED trolley
All the tools required (related to the machine) to perform the changeover are available in SMED trolley. Big stand is available in the left corner where all the tools are kept that will be needed during changeover, it helps to avoid Muda of Motion & Transportation
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SMED trolley contains all the tools required to perform quick changeover. SMED trolley has been parked only in the right area
Responsibility has been assigned to
Shift Fitter
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• Place for everything and every useful thing in its place (PEEP)• Kanban system• No stock out or over-stocking of material
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Kanban Collection
tray
Once any material has been picked up for use, the Kanban card of the particular material will go into the Kanban collection tray. It will then be sent to purchase department at every 11 am & 4 pm daily for placing the replenishment orders
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Whenever the operators need some material, they trigger the light that gives signal toMizusumashi (Water Spider) who replenishes the required material in the workstation
Mizusumashi (Water Spider)
Light signal
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Point of Use Storage (POUS) with Kanban
Responsibility assigned
Kanban Card
Kanban Board
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Visual Management
Count Free
No Oil Drops on the Floor
Name of the Oil stored
Same color marking is
done on M/C
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Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer
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Kaizen For kids (KFK)
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Yogesh Vaghani discussing the importance of Kaizen with School Faculty