lean activities - april 2014 update

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LEAN ACTIVITIES AT TVONE – QUARTER ONE REPORT Gaurav Bijlani Manufacturing Engineer April 2014

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Page 1: Lean activities - April 2014 update

LEAN ACTIVITIES AT TVONE – QUARTER ONE REPORT

Gaurav BijlaniManufacturing Engineer

April 2014

Page 2: Lean activities - April 2014 update

ACTIVITY BASED - NUMBER OF KAIZEN EVENTS - 1

Test area Kaizen event. Test area has several bottle necks, Operator training, equipment availability, Failures and also spof (Single point of failure). After meetings and data gathering, project objectives have been established. This is a Manufacturing based activity.

Number of participants – 6

Project started mid-February. Completion target date, end of June 2014.

Page 3: Lean activities - April 2014 update

NUMBER OF KAIZEN EVENTS

Training provided:

5S audits and criteria

5S training for core team members

7 + 1 Wastes (TIMWOODS)

SMED (Single minute exchange of Die)

Value Stream Mapping

Process Mapping

Page 4: Lean activities - April 2014 update

RESULT BASED

Safety – With cables neatly tucked away (Tie-wrapped) and neatly arranged, extension leads raised off the floor and at accessible height, tripping hazard is eradicated.

Delivery: Lead time reduced. Test operators suggested carrying out Testing products in a batch process rather than in smaller batch or individual units. This reduced setup time.

Page 5: Lean activities - April 2014 update

RESULT BASED

Employees trained in Lean fundamentals:

% of BU trained in Lean Fundamentals – 20%

Original figure, 16%.% of BU participating in Kaizen : 12%. This is the first time Kaizen event is taking place at tvONE.

Page 6: Lean activities - April 2014 update

Q1 SUCCESS STORY

5S activities implemented, Lean initiatives board in place, OTD and FTP monitored, programming capability in Test area increased 100% and batch processing introduced.

Aim is to complete Test area Kaizen event by the end of the second quarter and start Production area Kaizen, Process mapping Production area and initiating SMED in SMD.

Page 7: Lean activities - April 2014 update

Q2 TRAINING AND PROJECT PLANS

SMED and OEE training booked for 8th May.5S basics for all Production employees – In house training planning in progress.

Cost, Quality and Delivery training booked – 9th April.

Page 8: Lean activities - April 2014 update

2014 TARGETS

Carry out Process Mapping of at least 2 areas in the Production area and remap the area.

Improve Quality by measuring processes at every stage.

To continue 5S activities and complete at least 2 Kaizen events in the year.

Actively include every individual in Process improvements.