The fact that motivation is the most important factor for productivity and quality is not a new discovery Nevertheless, until recently The basic assumption was that is, to improve productivity and quality, it is necessary and sufficient to improve...
Shop floor observations include the overall design of the plant for production and internal logistics, as well as details that reveal how it is operated. You can tell whether it is a job-shop, a flow line, or a collection of flow lines. You can tell whether the flow of materials is visible, what kind of equipment is used for materials handling, and how much of the floor is used for warehousing versus production.
When you zoom in on individual stations, you can assess the level of automation and the attention that has been paid to the design of operator jobs.
You can also check out the accuracy of the signage, the presence and use of andons, mistake-proofing devices, production monitors, and team performance boards.
Several tools are available to help you see better, some of which require more than a quick visit. They include the following:
1) Using a Seven Wastes Checklist.
2) Following the flow.
3) Start counting people, machines, parts or fixtures.
4) Hunting for bugs.
5) Conducting video time studies.
“10 Questions asked on a Gemba Walk”:
1. What are the business issues with this product?
2. Who is responsible for the value stream for this product?
3. How are orders from the customer received?
4. Where is the pacemaker process, triggered by customer orders?
5. How capable, available, adequate, and waste-free are assembly activities?
6. How capable, available, adequate, and waste-free are the fabrication activities feeding assembly?
7. How are orders transmitted up the value stream from the pacemaker process?
8. How are materials supplied to the assembly and fabrication processes?
9. How are materials obtained from upstream suppliers?
10. How are employees trained in Lean procedures motivated to apply them?
Kanban Definition - Kanban is a visual system for managing work moving through a process – the “value stream”. Kanban is a system for visualizing work, reducing waste by limiting work in-progress, and maximizing customer value.
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