...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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...5S and applications 5S may be the first step for the company to embrace Lean strategy. 5S stands for five different characters which are sort, set in order, shine, standardize, and sustain. The 5S system is a tool, or system that supports a philosophy of operating in an organized fashion. The philosophy that this system supports is one of discipline, efficiency, and attention to detail (Graban, 2009). The idea behind 5S is that if a workplace is clean and well laid out, the identification of waste is much easier (Sarkar, 2005). 5S is a way to help the company to reduce the waste and enhance possible profits. 5S is used by five different Japanese words which are seiri, seiton, seiso, seiketsu and shitsuke and these focus on effective workplace and work procedure (Graban, 2009). Seiri, which is sort in English, helps the company or any organization to distinguish the items into two different categories: used and non-used (Breyfogle,2010). Seiton means set in order and it is focusing on making efficiency in the workplace by rearranging all items in the company which will promote work flow. All the tools should be set in the place where can improve work flow and it is easy to find for job (BusinessKnowledgeSource.com, paragraph 4, 2010). Seiso means to clean and clear. This step focuses on cleaning and clearing any item and working environment (The 5S plan Lean manufacturing solution, 2008). Seiketsu means standardize. To keep the first three Ss as the standard all the time and...
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...8 Management Services Spring 2012 Efficiency nformation 5S By Dan Markovitz. llison is an anaesthesiologist at a major hospital in New York. Real estate prices being what they are in the country's most expensive city, her office is only slightly bigger than a broom closet. Every horizontal surface of Allison's office (except for her chair) is covered - no, buried - in paper: printed-out emails, regular mail, departmental memos, receipts from the last conference she attended, a decade's worth of professional journals...well, you get the idea. The place is a monument to the paper products industry. Now, given that Allison does her clinical work in the operating room and doesn't see patients in her office, you might think that the mess is without consequence. After all, it only affects her, not the surgeons or the patients. Moreover, it only interferes with the administrative aspects of her job, not critical patient care issues. But you'd be wrong. Allison's hospital is also a teaching hospital, which means that she's expected to write grants to bring in funds for academic research and she's supposed to publish her findings. Want to guess how many A papers Allison has published in the past two years? Zero. She justifies her lack of academic productivity by explaining that her clinical responsibilities are so onerous that she has no time to find available grants and apply for them. To be fair, she does work a long day...
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...quality handbook: 9 5 Danish Standard 11 5.0.1 Standardise procedures 11 5.0.2 Quality documents 11 5.0.3 Supplier selection 12 5.0.4 Production control 12 5.0.5 Inspection 12 5.0.6 Handling of inventory 13 5.0.7 Customer feedback and needs 13 6 Current state 13 6.1 Processes 13 6.1.1 Welding 13 6.1.2 Painting 14 6.1.3 Assembly 14 6.2 Human recourse and training of new employees 15 6.3 Current quality system 15 6.3.1 5S at Dal-Bo 16 7 Data collecting 16 8 Data analysing 17 8.1 Pareto analysis 17 8.2 Ishikawa diagram (fishbone diagram) 19 8.3 Statistical Process Control 21 8.4 Sub conclusion 22 9 Lean boards 22 9.1 Lean boards at Dal-Bo 23 9.2 Content of a lean board 23 9.2.1 Quality goals and strategy: 23 9.2.2 Errors that occur and costs: 25 9.2.3 Customer feedback: 25 9.2.4 Improvement suggestions: 25 9.2.5 Productivity and on time delivery: 29 9.2.6 5S patrol: 29 9.2.7 Skills matrix: 32 9.2.8 Weekly lean-board meetings: 32 9.3 Location of boards 33 10 Quality handbook 33 10.1 Introduction 33 10.2 Delimitation 34 10.3 Content 35 10.4 Procedure no. 4: Painting inspection 36 10.4.1 Visual quality board 37 10.5 Procedure no. 3: Welding inspection 38 10.5.1 Radiography 40 10.5.2 Mechanical testing 40 10.6...
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...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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...maintenance work. The machines were being checked and repaired only after the breakdown. But with the industrialization, it became necessary to adopt new concepts to survive in the market. The organization decided to adopt “Total Productive Maintenance (TPM) for its survival. Problems Faced Due To Maintenance The importance of maintenance functions has increased due to its role in keeping and improving the availability, product quantity, safety requirements, as maintenance costs constitute an important part of the operating budget of manufacturing firms. The Company operated at less than full capacity, with low productivity, and the cost of producing products are high. Almost 25-30% of total production cost is attributed to maintenance activities in the factory. Hence the quality of maintenance significantly affects business profitability. There was a lot of variation in all manufacturing processes in the firm due lesser utilization of hardware resources and uneven investment in human resources due to lack of proper planning of each task significantly affecting the overall cost bore by the company. OEE before TPM Implementation First, we have to select the machines to study the TPM implementation. To start with TPM, a few machines have been...
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...hat attracts the eyes of so many people including celebrities. Nike has used various marketing techniques to get to the stage it’s at today and I am going to be describing what techniques it has used. My second organisation is apple. Apple is a Multinational Corporation that is known for the sales and design of computer electronics, computer software and personal computers. In recent years, apple came out with products such as I pads, I phones etc. These products became very popular in a short period of time thus giving apple an upper hand over its competitors. Marketing technique is the overall marketing plan that is designed to meet the needs and wants of customers. There are four main marketing techniques which are: Market penetration, market development, product development and Diversification. Market penetration: This is an activity that an organisation takes in order to increase the market share of an existing product or promoting a new product. Nike sells their products in stores and online. Their online market helps to increase the number of customers because there are some customers that do not have access to Nike stores in their local area. Nike promotes its products by allowing celebrities to advertise their products. For example, Tiger woods’ advertises Nike products; this might help increase the...
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...European School of Economics MSc Management INTERNATIONAL PROJECT MANAGEMENT The launch of the new IPhone 5S Lecturer: Vera Koubkova Students: Denisa Nicoara: 1205950 Horatiu Ilea: 1205948 Camilla Coriani Nicola Longo Date: 11th of March Word count: 2732 Table of Contents 1. Project Initiation Document: 2 1.1. The statement of client need: 2 1.2. The project team: 5 1.3. The Project Budget: 7 1.4. Risk Management 8 2. The Project Planning: 12 2.1. The Work Breakdown Structure: 12 2.2. The precedence for each activity on the Work Breakdown Structure: 14 2.3. The resources needed to complete the activities each day: 15 2.4. The Activity on Node Network Diagram: 15 2.5. The critical path: 15 References: 17 1. Project Initiation Document: We are a Project Management company, with twenty employees and four owners and managers at the same time: Denisa Nicoara, Camilla Coriani, Horatiu Ilea and Nicola Longo. 1.1. The statement of client need: The Apple team has asked us, the Orchid Project Management company to assign a team that is going to plan the launch of their new IPhone 5S. When Apple launches a new product, everything needs to be planned to the last detail and no one can know about what is going to happen during the launch, but everybody has to be talking about the launch long time before it takes place. The launch has to take place in San Francisco's Yerba Buena Center...
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...Lean Event (Kaizen Blitz) Agenda 1. What is Lean Event 2. Purpose of Lean Event 3. Lean Event Plan 4. Benefits of Lean Event Development of Lean Event (Kaizen Blitz) Kaizen Continuous incremental improvement Blitz To make a great effort to do something that needs to be done • • The origin of Lean Event concepts are pioneered by Toyota Production System. The concepts enabled the Toyota Production System to be the best in the world. Definition of Lean Event 1. Kaizen Activity – which means small step increment or continuous improvement activities 2. Short-term, intensive and focus effort to dramatically to improve the performance of a limited scope process. 3. Process for improving QDC by eliminating wastes 4. Process for learning Lean Manufacturing techniques 5. Technique to simplify existing processes with minimum money and maximum use of the people who daily make them work 6. The beginning of Lean transformation on the production shop floor Purpose of Lean Event 1. Speed of improvements can be realized quickly 2. Team are focused and free from daily operational issues 3. Team are creative and practical ideas are generated. 4. Intensity and urgency overcomes the intellectual resistance to new paradigm or ideas 5. Results generated are significant, clear and quick which will translate into enthusiasm and satisfaction. 6. Human development are enhanced as lean knowledge are being applied and transfer by relevant parties 7. Enhanced Learning by Doing Lean Event Principles...
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...Mechanical Engineers Qualities for Millennium 3 1) Bachelor’s Degree/Diploma in Mechanical Engineering or its equivalent. The mechanical engineer has been called the general practitioner and the jack-of-all trades among engineering professions. This is because he requires education and skills that span a broad range of technical, social, environmental, and economic problems. In general, however, the mechanical engineer is concerned with controlling the principles of motion, energy, and force through mechanical solutions. A mechanical engineer designs the tools and processes used for satisfying the needs of society through a combination of material, human, and economic resources. He might work on electric generators, internal combustion engines, steam and gas turbines, and other power-generating machines. He might also develop machines such as refrigeration and air-conditioning equipment, power tools, and other power-using machines. Engineers must combine a good understanding of science, mathematics, and computers with a good knowledge of current technology. At the high school level, the emphasis is on mathematics. Two years of algebra plus courses in geometry and trigonometry generally are required. In addition to the sciences and math, engineers need good communication skills, so don't neglect the liberal arts and humanities. In addition, remember that many of the large industrial firms that employ mechanical engineers are multinational...
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...PCB Manufacturing Printed circuit boards are made by etching or ‘printing’ wires on a copper conductive laminated thin fiberglass or other similar material board. This insulated board is also known as substrate. PCB will function as an electronic circuit as conductive connections are created when active electronic components (e.g.: microchips, transistors) and passive components (e.g.: capacitors, fuses) are mounted on a PCB. There are three basic types of printed circuit boards: i ) single sided PCB ii ) double sided PCB iii) multi layered 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...
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...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 the goal(s). This must be a team activity to ensure that everyone is given the opportunity to contribute...
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...PENILAIAN PENGIKTIRAFAN PENGURUSAN KUALITI MENYELURUH BERDASARKAN TOTAL QUALITY FAST TRACK MODEL (TQFTM) untuk: Universiti Tenaga Nasional (UNITEN) SDN. Tarikh Penilaian : 1 & 3 Jun 2011 Penilai : Dr. Mohd. Azman Idris En. Safuan Idris En. Idrus Ali Pn. Faizah Baba Pn. Aliza Zainal Munir Disediakan oleh; PUSAT PENGURUSAN KUALITI & PERUSAHAAN, SIRIM Berhad Segala maklumat yang terkandung dalam laporan ini adalah milik penuh SIRIM Berhad dan merupakan maklumat komersial yang khusus untuk UNITEN. (17 Jun 2011) SIRIM Berhad Penggunaan atau pendedahan segala maklumat adalah tertakluk kepada perkara yang dinyatakan di muka surat hadapan dokumen ini PENGENALAN Penilaian Pengiktirafan Pengurusan Kualiti Menyeluruh berdasarkan Total Quality Fast Track Model (TQFTM) dilaksana pada 1 Jun 2011 di Kolej Pengurusan Perniagaan & Perakaunan (COBA) di UNITEN Kampus Sultan Haji Ahmad Shah, Bandar Muadzam Shah, Pahang, manakala pada 3 Jun 2011, penilaian dilaksanakan di UNITEN Kampus Putrajaya bagi Bahagian Pengurusan Universiti, Kolej Kejuruteraan, IT dan Asas & Pengajian Am. Penilaian bertujuan untuk mengenalpasti amalan dan pelaksanaan di UNITEN berbanding kriteria penilaian TQFTM sebelum UNITEN dianugerahkan dengan sijil TQFTM SIRIM Berhad. Hasil penilaian ini juga akan membantu UNITEN mengenalpasti ruang - ruang peningkatan dalam pengurusan kualiti operasi keseluruhan organisasi untuk membantu UNITEN dalam usaha yang berterusan ke arah...
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...Contents Introduction3 The Meaning of Kaizen3 History4 Goals of Kaizen4 Tools of Kaizen6 Implementing Kaizen7 An Example of Kaizen9 Other Applications11 Conclusion12 Bibliography13 INTRODUCTION Kaizen is an idea with humble beginnings that has taken hold of the manufacturing world and grown to become a powerful tool that can be harnessed to become a dominate player in the industrial world. The philosophy of Kaizen is a simple idea. It aims to continually make small changes anywhere it can in a process in order to improve the overall process. Kaizen focuses on a few key concepts to create a lean manufacturing system. The Kaizen system includes many components such as quality circles, just-in-time delivery, 5S, kanban, and many more. These tools are utilized to implement Kaizen. The Kaizen philosophy has been applied to many different industries all around the world. THE MEANING OF KAIZEN The Business Dictionary defines Kaizen as the “Japanese term for a gradual approach to ever higher standards in quality enhancement and waste reduction, through small but continual improvements involving everyone from the chief executive to the lowest level workers.” ("Kaizen") There are a few key phrases in this definition that truly illustrates the Kaizen way of thinking. First, this definition states that Kaizen is an approach to achieve “ever higher standards”. The Kaizen philosophy drives companies to work toward the highest standards. This means that...
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...I thought this was a good article to share as it clears some misconceptions of Toyota and their management philosophies and technology. This article was written by Stewart Anderson who is president of http://www.kaizenimprovement.ca a Toronto-based consulting and advisory firm in the areas of continuous improvement and business strategy. The tools and techniques of what is commonly called "lean manufacturing" have their origin in the Toyota Production System (TPS). While the lean movement deserves much credit for popularizing these tools and techniques, a number of misconceptions appear to have developed about how Toyota itself actually practices continuous improvement. This article looks at some of these misconceptions. Readers should note that this article is not meant to be a definitive study of Toyota, nor is it meant to supplant the excellently detailed analyses of Toyota published by Jeffrey K. Liker (The Toyota Way, McGraw-Hill, 2003), Steven J. Spear (Chasing the Rabbit, McGraw-Hill, 2008), and others. Rather, it offers the author’s own personal perspective and insights on Toyota, drawing from observation and study of Toyota production and distribution operations, supplemented by interviews with Toyota employees, managers, and suppliers held over the years. Some of the thoughts expressed below also find deeper expression and treatment in Mike Rother' excellent new book, Toyota Kata (McGraw-Hill, 2009), and readers are referred to that book for a full exposition of...
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