Continuous Flow Manufacturing
Kaizen Blitz
A
Kaizen Blitz is a very intensive and focused approach to Process
Improvement. A specific process is selected
for analysis by a multi-functional team of people. The team defines the current process by use
of flow charting, process mapping, process performance measures, and process
observation. Thereafter, the team
re-designs the process in such a way that will result in substantial
improvements in most, if not all process performance measures. Whenever possible, elements of the new
process are implemented during the Kaizen Blitz, and the results verified.
This approach can be used to implement Continuous Flow
Manufacturing concepts in a production operation. A three (3) day Kaizen event is conducted in
the production area. A team of internal
personnel is identified, and is facilitated through an eight step approach to
implement Continuous Flow Manufacturing concepts. Education in Continuous Flow Manufacturing
concepts is a part of the event. When
circumstances allow, the new process is actually implemented and the results verified. When not possible, the organization is left
with: a layout of the proposed process; projected performance measures for the
new process; detailed work station designs; an implementation plan and actions
list. Approximately 75% - 80% of all
events result in actual physical changes by the end of the three (3) day Kaizen
Blitz.
The process performance measures that are used are as
follows (along with typical results):
·
Cycle Time - up
to 95% reduction
·
Distance Traveled - up
to 80% reduction
·
Space Utilization - up
to 70% reduction
·
Work-in-Process - up
to 90% reduction
·
Productivity - up
to 40% increase
·
Quality Yields - 25%
- 75% increase
Typical Three (3) Day Agenda
Pre-event: Scoping – identify
product family to be subject of event
Determine work content, and nature of equipment
involved.
Day 1: Education in basic concepts
Document
current process
Observe
current process – time operations
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Typical 3-Day Agenda (continued)
Day 2: Calculate Takt Time
Develop work combination to balance process
Design new layout
Establish methods to
support flow – plan for every part
Establish performance
expectations
Day 3: Implement new process
Confirm performance of new process
Develop follow-up plan
The actual number of days
required will depend on the amount of work content for the product family that
is the subject of the event, as well as the ease of movement of the equipment
involved.
Typical Deliverables
·
Actual implementation
of the new layout, if time permits. A proposed process layout or layouts, with
recommendation(s) for locating the proposed process in the existing facility if
physical movement is not possible during the event.
·
Projected
benefits of the proposed process, per the performance measures used. Demonstrated results are often possible
during the event itself.
·
Detailed
documentation on new process design (e.g. standard work combination sheets,
plan for every process)
·
Actions List that
can be used to follow-up on any ideas, issues, etc. that could not be addressed
during the kaizen event.
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Management Associates Tele: 856-235-8051 • Website:
cma4results.com |
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Continuous Flow Manufacturing
One Day Workshop
Participants
will learn in depth Continuous Flow Manufacturing concepts. These concepts can be applied to any area
within the operation, even some non-production areas. The concepts covered will include Takt Time, Standard
Work, Work Combination and Line Balancing, Work Station Design, Layout Design,
Plan for Every Part, and Flow Management techniques.
A
simulation will be conducted to demonstrate the difference between “push”
versus “pull” versus “continuous flow” concepts. With use of the simulation, the participants
will witness first hand the substantial impact of the application of continuous
flow concepts. Numerous photographed
examples will be provided to enhance the learning experience.
The
various “tools” used in the creation of continuous flow lines will also be used
including Process Observation forms, Standard Work combination sheets, Capacity
Analysis forms, Operator Balance Charts, and others. These tools are invaluable when re-designing
existing production lines based on continuous flow concepts.
Duration: One day
Who should attend:
anyone who works in a manufacturing or production, including
managers. Office personnel that support
the production process can also benefit by attending this workshop. The concepts can also be applied to
non-production transactional processes often found in some office
environments. Therefore, people who work
in such areas would also benefit.
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Management Associates Tele: 856-235-8051 • Website:
cma4results.com |
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