Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line, 1st Edition (Hardback) book cover

Kaizen Assembly

Designing, Constructing, and Managing a Lean Assembly Line, 1st Edition

By Chris A. Ortiz

CRC Press

260 pages | 122 B/W Illus.

Purchasing Options:$ = USD
Hardback: 9780849371875
pub: 2006-06-26
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Description

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.

Table of Contents

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

Subject Categories

BISAC Subject Codes/Headings:
BUS070050
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
TEC016000
TECHNOLOGY & ENGINEERING / Industrial Design / General
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing