...5S SUMMARY 5S is a systematic approach to good house keeping. It is gaining a strong supporting most industries in Japan today, and there is an increasing number of companies which are implementing 5S with greater involvement of people within the organisation. Why is it becoming popular among companies in Japan? Simply because: 1) Workplaces become clean and better organised. 2) Shopfloor and office operation become easier and safer. 3) Results are visible to everyone – Insider and outsider. 4) Visible results enhance generation of more and new ideas. 5) People are automatically disciplined. 6) People become proud of clean and organised workplace. 7) Resultant good company Image generates more business, etc. Some significant benefits observed at companies practising 5S in Singapore include: 1. Happier people involvement 2. Greater people involvement. 3. Low employee turnover. 4. Increased number of suggestions. 5. Better use of floor space. 6. Less work-in-progress and inventories 7. Better flow of work 8. Low machine breakdown rates 9. Low accident rates 10. High yield of materials 11. High product quality 12. The assumption of why 5S is becoming so popular in Japan in recent years and now in other countries today is that it emphasises a people-oriented and also practice –oriented approach. 5S expects everyone – indeed, everyone to participate in it. It is based on the belief that every individual can contribute to improving his workplace...
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...A 5s Implementation Plan For The Shipping Department at Helical Products Co. By Eric William Walker A Senior Project submitted In partial fulfillment of the requirements for the degree of Bachelor of Science in Industrial Engineering California Polytechnic State University San Luis Obispo Graded by: Checked by: Date of Submission: Approved by: EXECUTIVE SUMMARY Helical Products Company is a business that manufactures flexure products, such as couplings and u-joints. As part of a movement towards lean manufacturing, Helical Products Company of Santa Maria, California is need of a principle that will help them continuously improve their shipping department. A study of 5S, a lean principle focused on waste reduction, will be done to investigate opportunity for implementation. A literature review takes a peek on research of lean manufacturing history, lean workbook/ tutorials and lastly case studies and journal articles. The output of research provides a design plan for Helical using 5S and other lean principles compatible with 5S, such as error proofing and Value Stream Mapping. A list of suggestions based on analysis and feedback from the Helical shipping department is provided. Lastly, a 5S manual catered for Helical Products Company is attached in the appendix. 1 TABLE OF CONTENTS Executive Summary....................................................................................................................................... 1 Introduction .......
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...be in the areas of quality and safety within a production environment. I will identify and compare established well defined process improvement methods, as well as, provide a series of recommendations that, if implemented, will assist with the fictional organizational goal that has been requested by the department managers at this company. Principals of Lean Manufacturing Lean Manufacturing is defined as a production practice that uses less and fewer resources than traditional manufacturing. The primary objective of implementation of lean processes is to eliminate any element of the process that does not add value and striving for perfection with zero defects and zero inventories. (Lynch, 2005) There are various principals to lean manufacturing that can be applied to any area of an organization to realize the process improvement in the assignment below I will discuss three examples 5s, Six Sigma and Kaizen. Process Improvement-5S 5S is a system that reduces waste and optimizes productivity through an orderly workplace and using visual cues to obtain more consistent results of the operation. Created first by Toyota Production Company, a Japanese based company, the five pillars in this process are: Sort (Seiri) Eliminating unnecessary item...
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...challenge; hence implementing lean techniques in a textile industry has been taken up as a challenge. We have chosen a combination of value stream mapping (VSM), 5S, kanban, kaizen, poka-yoke, and visual controls to improve the processes. The findings of this study reveal that a thorough analysis of the process, setup, and changeover time (CO), use of colour coding for identification of volume-mix, use of kaizen and quality circles which empower the workforce, are some of the various keys to a successful lean implementation in a textile industry. Keywords:Project manegement; lean manufacturing; agile manufacturing; value stream mapping; VSM; supply chain management. 1 Introduction What Is a Project Manager? SECTION 1: INTRODUCTION TO PROJECT MANAGEMENT Project management is the art of matching a project's goals, tasks, and resources to accomplish a goal as needed. We say "as needed" because one has limited time, money, and resources (human and machinery) with which to accomplish a goal. One can think of a project as a process. Figure 1 shows this process as a simplified block diagram. Figure 1: Simple Project Management System The process involves inputs and outputs. Successful projects "do the right things, with the right tools, and in the right way". SECTION 2: STAGES OF A PROJECT AND HOW TO COMPLETE THEM Stage 1: Defining the goals of the project: Garbage in equals garbage out. If you do not start a project with the correct goal(s), it is not likely you will accomplish...
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...UNLV Theses/Dissertations/Professional Papers/Capstones 10-1-2011 Lean and Six Sigma in Hospitality Organizations: Benefits, Challenges, and Implementation Justin M. Lancaster University of Nevada, Las Vegas Follow this and additional works at: http://digitalscholarship.unlv.edu/thesesdissertations Part of the Business Administration, Management, and Operations Commons, Hospitality Administration and Management Commons, and the Strategic Management Policy Commons Repository Citation Lancaster, Justin M., "Lean and Six Sigma in Hospitality Organizations: Benefits, Challenges, and Implementation" (2011). UNLV Theses/Dissertations/Professional Papers/Capstones. Paper 1150. This Professional Paper is brought to you for free and open access by Digital Scholarship@UNLV. It has been accepted for inclusion in UNLV Theses/ Dissertations/Professional Papers/Capstones by an authorized administrator of Digital Scholarship@UNLV. For more information, please contact marianne.buehler@unlv.edu. 1 Lean and Six Sigma in Hospitality Organizations: Benefits, Challenges, and Implementation. By Justin M. Lancaster Masters of Science University of Nevada Las Vegas 2011 A professional paper submitted in partial fulfillment of the requirements for the Master of Science Hotel Administration William F. Harrah College of Hotel Administration Graduate College University of Nevada, Las Vegas December 2011 Chair: Dr. Robert Woods 2 PART ONE Introduction The hospitality...
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...costs are managed over the life cycle of the product. Product life cycle begins from conception of the product until its abandonment which can be referred as ‘from cradle to grave‘. Product life cycle has four stages: 1) Product planning and initial concept design It involves process of identifying any underlying conditions, assumption, limitations and constraints such as minimum asset performance, maximum capital costs that might restrict the range of acceptable options to be evaluated. It is a valuable reference for better decision whether the plan should be carried on. This includes the research and development cost market research costs. 2) Product design and development Starting from preparation of development contract until equipment is ready to be introduced to the business. It is also a stage where the factory trials take place. Cost of product design, prototyping, and market testing costs. 3) Production All the manufacturing costs related to producing the products such as direct material, labor, overhead and administrative costs will be incurred. 4) Distribution and customer (or logistical) support This stage is where product are sent to customers and ready to be used. All marketing, selling and distribution costs are incurred at this stage. As for logical support cost, it involves delivery and transportation costs, warehousing costs, dismantling cost and costs for abandonment of the project and some equipment might need to be disposed of or recycled...
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...LSS lean Six Sigma Abstract Purpose – Although research has been undertaken on the implementation of lean within various industries, the many tools and techniques that form the “tool box”, and its integration with Six Sigma (mainly through case studies and action research), there has been little written on the journey towards the integration of the two approaches. This paper aims to examine the integration of lean principles with Six Sigma methodology as a coherent approach to continuous improvement, and provides a conceptual model for their successful integration. Design/methodology/approach – Desk research and a literature review of each separate approach is provided, followed by a view of the literature of the integrated approach. Findings – No standard framework for lean Six Sigma or its implementation exists. A systematic approach needs to be adopted, which optimises systems as a whole, focusing the right strategies in the correct places. Originality/value – This paper contributes to knowledge by providing an insight into the evolution of the lean Six Sigma paradigm. It is suggested that a clear integration of the two approaches must be achieved, with sufficient scientific underpinning. Keywords Lean production, Six sigma Paper type Literature review 1. Introduction The Toyota Production System (TPS) provided the basis for what is now known as lean thinking, as popularised by Womack and Jones (1996). The development of this approach to manufacturing began shortly after...
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...PCB PCB is commonly used in making electronic devices such as computers, home entertainment equipments, telephones, etc. 1.1 Company Background X Electronics (M) Ltd. is a subsidiary company build in north Malaysia during 1990. X Electronics (M) Ltd. headquarters are in Singapore. It started the Malaysian branch operation in 1991. X Electronics specializes in PCB production process from design and development stages to assembly stages. X Electronic caters flexible production whether it is mass volume or low volume production. The Process [pic] Figure 1 : X Electronics (M) Ltd. (Image taken from Google Image for PCB manufacturing plant layout) X Electronics (M) Ltd. facilities have already applied several lean tools in its PCB manufacturing processes. The company is committed to achieve short lead time delivery and low cost production by optimizing its humans, machines and material resources. Figure 2 : PCB Assembly Process (Image taken from Google Image) [pic] 1. Implementation of Lean in PCB Manufacturing Lean Application X Electronics begin applying lean tools in its manufacturing process in 2004 after receiving direct order from its headquarters in Singapore. This is due to lean being the main topic in...
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...INTRODUCTION Manufacturing has been recognized as the main engine for growth of the economy. Ever changing globalized environment has been posing challenges of competitiveness and survival to all the constituents of the economy. Manufacturers industry have always faced heightened challenges such as rising customer’s demand for better and improved products, erratic demand, and competition in markets. There is no disbelief that the manufacturers are always embracing changes and improvements in their key activities or processes to cope with the ever growing challenges. To be more efficient is the only way to stay and earn profit in a global market. Industries are giving lot of attention to Lean manufacturing. Several industries are struggling to be world class. Principal adoption of lean manufacturing is still found to be complex. Lean Manufacturing is a set of techniques, which have developed gradually over a long period and are based on various minor to major breakthroughs that help in reducing cost and hence increase productivity. Lean is a philosophy of manufacturing that incorporates a collection of principles, tools and techniques into the business processes to optimize time, productivity, HR, and assets, while improving the quality level of products and services to their customers. LEAN MANUFACTURING Lean manufacturing is defined as to produce same and more than the mass production using less effort, lesser space, without any new inventory, better quality and lesser defects...
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...Introduction to 6S at Joy Global JOSH OLSON ASHWINI PATIL EDGAR AMACA DR. HAMID SEIFODDINI IE 587: LEAN MANUFACTURING SYSTEMS SPRING 2014 MAY 06, 2014 Abstract Our project team tasked ourselves with taking a real-world application of LEAN manufacturing, 6S, and bringing it into the classroom to better demonstrate how the Industrial Engineering tools learned at a university can and are being used every day in industries local as well as abroad. To do this, a local manufacture of heavy industrial equipment, Joy Global Inc. was visited and examined to determine how a large corporation determines if 6S is appropriate to implement into the company, as well as how the organization approaches integrating each pillar of the 6S process into its own processes, corporate culture, and company values. Each step of the process was examined and before and after examples were drawn out to demonstrate the increased productivity, safety, and effectiveness that a process can have when 6S is properly implemented. 1 Chapter 1 Introduction One contribution of the LEAN approach to manufacturing, industrial or any business improvement has been a set of tools that anyone can leverage to improve workplaces and work processes. One of these tools is known as 6S. Most people may think of it as relating to manufacturing workplaces, but it is just as applicable to office settings or even one’s garage space. As with all LEAN tools, 6S is about eliminating waste...
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...Page|1 APPLICATION OF INDUSTRIAL ENGINEERING In Garments Sewing Floor Sabya Sachi Roy ID: 081-23-750 Subodh Kumar Ghosh ID: 081-23-737 AND Ripon Chakraborty ID: 081-23-744 This Report Presented in Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in Textile Engineering Supervised By Engr. Md. Mahfuzur Rahman Senior Lecturer Department of Textile Engineering Daffodil International University DAFFODIL INTERNATIONAL UNIVERSITY DHAKA, BANGLADESH JANUARY 2012 ©Daffodil International University Page|2 DECLARATION We hereby declare that, this project has been done by us under the supervision of Engr. Md.Mahfuzur Rahman, Senior Lecturer, Department of Textile Engineering, Daffodil International University. We also declare that neither this project not any part of this project has been submitted elsewhere for award of any degree or diploma. Supervised by: Engr. Md.Mahfuzur Rahman Senior Lecturer Department of Textile Engineering Daffodil International University Submitted by: Sabya Sachi Roy ID: 081-23-750 Department of TE Daffodil International University Subodh Kumar Ghosh ID: 081-23-737 Department of TE Daffodil International University Ripon Chakraborty ID: 081-23-744 Department of TE Daffodil International University Page|3 Acknowledgement We would like to thank Senior lecturer Md.Mahfuzur Rahman for his leadership and guidance in helping us find our niche in Industrial Engineer. Without his help we would...
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...Business Process Management Journal A systematic review of Lean Six Sigma for the manufacturing industry Saja Ahmed Albliwi Jiju Antony Sarina Abdul halim Lim Article information: Downloaded by North South University At 22:57 26 January 2016 (PT) To cite this document: Saja Ahmed Albliwi Jiju Antony Sarina Abdul halim Lim , (2015),"A systematic review of Lean Six Sigma for the manufacturing industry", Business Process Management Journal, Vol. 21 Iss 3 pp. 665 - 691 Permanent link to this document: http://dx.doi.org/10.1108/BPMJ-03-2014-0019 Downloaded on: 26 January 2016, At: 22:57 (PT) References: this document contains references to 63 other documents. To copy this document: permissions@emeraldinsight.com The fulltext of this document has been downloaded 961 times since 2015* Users who downloaded this article also downloaded: Saja Albliwi, Jiju Antony, Sarina Abdul Halim Lim, Ton van der Wiele, (2014),"Critical failure factors of Lean Six Sigma: a systematic literature review", International Journal of Quality & Reliability Management, Vol. 31 Iss 9 pp. 1012-1030 http://dx.doi.org/10.1108/IJQRM-09-2013-0147 M.P.J. Pepper, T.A. Spedding, (2010),"The evolution of lean Six Sigma", International Journal of Quality & Reliability Management, Vol. 27 Iss 2 pp. 138-155 http:// dx.doi.org/10.1108/02656711011014276 Diego Pacheco, Isaac Pergher, Guilherme Luís Roehe Vaccaro, Carlos Fernando Jung, Carla ten Caten, (2015),"18 comparative aspects between...
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...Introduction In race to be a leader, most companies are realizing that traditional management, manufacturing processes, and other orthodox approaches, are not enough. More effective methods are needed: • Lean Manufacturing • Six Sigma Lean “Lean is a way to specify value, line up value-creating actions in the best sequence, conduct those activities without interruption whenever someone requests them, and perform them more and more effectively. In short, lean thinking is lean because it provides a way to do more and more with less and less – less human effort, less human equipment, less time, and less space – while coming closer and closer to providing customers with exactly what they want.”- Womack and Jones (1996). “Becoming ‘lean’ is a process of eliminating waste with the goal of creating value.” – Womack & Jones There are FIVE overriding principles to Lean. Identify Customers and Specify Value - The starting point is to recognise that only a small fraction of the total time and effort in any organisation actually adds value for the end customer. By clearly defining Value for a specific product or service from the end customer’s perspective, all the non value activities - or waste - can be targeted for removal. Identify and Map the Value Stream – The Value Stream is the entire set of activities across all parts of the organisation involved in jointly delivering the product or service. This represents the end-to-end process that delivers the value to the...
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...customers and the importance given to effective marketing………………………………………………………………. 20 2. Evaluate the benefit of user and non-user survey in determining customer needs……………………………………………………………………………… 21 3. Examine the methods of consultations employed in one quality scheme to encourage participation by under-represented groups……………………………………… 22-23 4. Investigate the value of complains procedure at two different centers and analyze how each is used to improve quality……………………………………………… 24-25 Task 4 1. Identify the role of self assessment in order to determine an organization’s current ‘state of health’………………………………………………………………………. 26 2. Explain the stages staff consultation necessary for effective implementation of a quality scheme………………………………………………………………………. 27-28 3. Propose new system or modifications to existing system that could improve service quality………………………………………………………………………………… 29-30 References 31 INTORDUCTION...
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...GOVERNMENT OF INDIA GUIDELINES For the Implementation of Lean Manufacturing Competitiveness Scheme A Component of National Manufacturing Competitiveness Programme Development Commissioner Micro, Small & Medium Enterprises Government of India Nirman Bhavan, New Delhi-110 108 www.dcmsme.gov.in May, 2010 Published by The Development Commissioner, Micro, Small & Medium Enterprises, Nirman Bhavan, New Delhi-110108 Printed at Tara Art Printers Pvt. Ltd., B-4, Hans Bhavan, B.S. Zafar Marg, New Delhi-110002 National Manufacturing Competitiveness Programme 4 Lean Manufacturing Competitiveness Scheme CONTENTS Sl. No. Subject Preface 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Introduction Overview The Scheme Concept Objectives of Lean Manufacturing Scheme Develoment Commissioner (MSME) Implementation Structure Financial Assistance Coverage and Eligibility Implementation Framework Implementation Time Line Approval Process Modalities of Fund Transfer Format for Application by MCs/SPV – Annexure - 1 Power of Attorney – Annexure - 2 7 7 7 9 9 9 10 10 10 14 14 14 16 18 Page No. 5 National Manufacturing Competitiveness Programme ABBREVIATIONS CMTI CPs DC (MSME) DGFASLI GDP GOI IA IFW ILO LMC LMS MC MSME MSME - DI NMCC NMCP NMIU SPV SSC T&C TAC – – – – – – – – – – – – – – – – – – – – – Central Manufacturing Technology Institute Condition Precedents Development Commissioner (MSME) Director General Factory Advice Service & Labour Institutes Gross Domestic...
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