...12/11/2013 5 @ L.N. Welingkar Institute of Management Bangalore Gorur Consultancy Gorur N Sridhar Quality Consultant What to expect? GC 5S – 5 C concepts 5S implementation stages Examples 2 1 12/11/2013 GC Learn What 5S is and How it Applies to Any Industry Video 3 GC 5S – 5C 4 2 12/11/2013 5S - Seiri, Seiton, Seiso, Seiketsu and Shitsuke GC 5S is a tool within the arsenal of Lean Manufacturing, it is a lean tool that helps you to organize your workspace in a manner that is more efficient, safer and more visually appealing. It is not as some people think purely a housekeeping process, this is work place organisation. 5S is a methodical, sustainable approach to work place organization that when implemented correctly can give you efficiency savings of between 10% and 30%. These are not the only improvements, there are many benefits of 5S. 5S is not just applicable to the factory floor where most people would apply it, it is just as important to apply the principles of 5S in the lean office or even on your computer drives. 5 5S – 5C GC 6 3 12/11/2013 GC Implemen tation 7 5S Seiri or Sort - Stage 1 The first stage of 5S within lean manufacturing is that of Seiri or sort, removal of all clutter that is within the working area. This is a step that should be participated in by everyone. Obvious junk should treated as junk and skipped. be GC Items that are too heavy that are not required, in need...
Words: 1246 - Pages: 5
...223-224) 1. Utilization would be the method I would use to measure the where you would need to add extra capacity or eliminate extra space. In this case we would see that cardio is reaching maximum capacity. Fitness plus has not reached its capacity but it is time to start doing something about space. Capacity could soon be met since the area is growing so fast. January is also going to get busy so it is time to act. 2. The capacity strategy that would be best for Fitness Plus would be sizing capacity cushion which would help to find out if you are reaching a 100% utilization rate. You would then be able to gauge whether you need to increase capacity before it becomes a production issue. It would be ideal to stay around a 40% cushion so that you can keep customers satisfied and to avoid any problems. 3. The operating decisions are directly related to the financial aspects of the business. By increasing membership and utilization you increase profits which is what any business should want. Making changes to the business to meet increasing demand will affect other types of operating decisions in the business. You would have to change marketing and customer service. 2. Experiential Learning: Min-Yo Garment Company (from chapter 7 on constraint management; pages 269-272; question 1 only) Production is not within capacity it is way over. 3. Video Case: Lean Systems at Autoliv (from chapter 8 on lean systems; pages 303-304) 1. Visual management is when a visual...
Words: 727 - Pages: 3
...as required. (Apply ME Poka Yoke recommendations to improve Mfg performance.) • Implement visible workplace controls, i.e., clear identification of Mfg cells, Mfg trend charts, 5s bulletin boards. • Increase department expertise through cross-training as a means to augment the caliber of higher level assembly personnel. • Expand prep-station responsibilities to include hardware kitting, pre-made labels, ground straps, and one-end wire terminations. Expand prep-station as new Mfg needs develop. Implement 5s practices and mindset; sustain improvements...
Words: 515 - Pages: 3
...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...
Words: 1191 - Pages: 5
...outlets. The Company recently installed the YMS (Yard Management System), which we have integrated with our WMS (Warehouse Management System) and TMS (Transport Management System). Our expectation was improved performance in over-a-road transportation equipment utilization, driver productivity, and warehouse dock/door utilization. Our company is No.1 distribution in the country and we have 80% of local markets to supply. A warehouse management system (WMS) is a key part of the supply chain and primarily aims to control the movement and storage of materials within a warehouse and process the associated transactions, including shipping, receiving, put away , Label printing, Storage, Inventory control, ordering fulfillment, Cycle counting and picking. A WMS monitors the progress of products through the warehouse. It involves the physical warehouse infrastructure, tracking systems, and communication between product stations. More precisely, warehouse management involves the receipt, storage and movement of goods, (normally finished goods), to intermediate storage locations or to a final customer. Warehouse management is an aspect of logistics and management. A WMS fully automates and streamlines the entire order fulfillment process with higher efficiency. For total visibility, flexibility and scalability, WMS provides our organization with the key to bigger success with just a click away. A Transportation Management System (TMS) is a software and helping business and organizations...
Words: 2108 - Pages: 9
...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...
Words: 4218 - Pages: 17
...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...
Words: 12664 - Pages: 51
...LEAN SYSTEMS Reduction in inventory because of robots. Quick and faster. Change the layouts and set-ups. Is learning organization approach for designing supply chain system known as lean system. Lean systems are operation systems that maximize the value added by each of the companies activities by removing waste and delays from them. It is making more efficient, more quicker and faster( is lean system). Lean systems develop more efficient manufacturing operations. What is JIT just in time-that incorporates generic elements of lean system by cutting unnecessary capacity or inventory and removing non value added activities in operations. Eliminates waste or muda. 8 types of wastes : 1 over production, 2) in appropriate processing,3) waiting, 8) transportation( Excessive handling during transportation), 4) motion, 5) Inventory , 6) defects and 7) underutilization of employees. JIT system organizes the resources, information flow and decisions that enables firm to realize the benefits of JIT principle. Lean system leads to continuous improvement in quality and productivity. The Japanese term for this approach to process improvement is KAIZEN. Hides underlying problems with processes that produce service or product. Service processes improved : scheduling, billing, order taking, accounting, financial planning . SUPPLY CHAIN CONSIDERATIONS IN LEAN SYSTEMS : 2 characterstics of lean systems that are related to creating nad managing material flows in a supply chain ;...
Words: 3231 - Pages: 13
...by Pernas-OUE of Malaysia and managed by Singapore Mandarin International Hotels.Penang Mutiara wants to give to its customer the quality of service. And it also wants to give everything what its guests’ wants and needs. Penang Mutiara’s objectives are to give fast response to every customer request (SPEED), to keep its promise to be of service to their guests (DEPENDABILITY), and to be flexible to every guest request. The hotel believes that it is the impeccable customer service they are giving to their guests which gives them competitive advantage. The hotel is very careful never to compromise the quality of its service in order to cut costs. Good service means that guest s return again and again. The more guests, the higher utilization of rooms and restaurants, so in the end, it’s the quality of our service which keeps the hotel’s volume high and costs low. STATEMENT OF THE PROBLEM How to improve the operations and sustain the competitiveness of Penang Mutiara as a leading hotel in Southeast Asia. OBJECTIVES 1. To be able to identify new operation strategies for Penang Mutiara to continuously give its guests the quality hotel service. 2. To be able to identify areas in operations wherein...
Words: 1419 - Pages: 6
...C . T . Bauer C o ll ege o f Busi ness Suppl y C hai n Managem ent D epar tment o f D ec i si o n an d Info r mati o n Sci ences Managing Productivity and Quality Mondays and Wednesdays (Melcher 114) Fall Semester, 2014 Professor: E-mail: Office: Office Hours: Course Website: LinkedIn: Course Materials: Books: Widely available at a discount through online retailers such as amazon.com The Lean Toolbox: The Essential Guide to Lean Transformation, Fourth Edition John Bicheno & Matthias Holweg, PICSIE, 2008/2009 Velocity: A Business Novel Dee Jacob, Suzan Bergland, and Jeff Cox, Free Press, 2010 The Memory Jogger 2, Second Edition Michael Brassard and Diane Ritter, Goal/QPC, 2010 (www.goalqpc.com) The Lean 6 Sigma Deployment Memory Jogger, Second Edition Jaime Villafuerte, Goal/QPC, 2013 (www.goalqpc.com) Cases and Articles: HARVARD BUSINESS REVIEW: https://cb.hbsp.harvard.edu/cbmp/access/27592786 NOTE: HBR articles and cases must be purchased to comply with copyright restrictions Dr. Bradley Miller bmiller11@uh.edu Melcher Hall, Room 270A Immediately following class or by appointment Blackboard http://www.linkedin.com/pub/bradley-miller/63/7a5/66a/ UH LIBRARY: http://guides.lib.uh.edu/MPQ (free) BLACKBOARD: Course Documents Folder (free) Course Notes & Resources Note slides are posted to Blackboard (Course Lecture File) prior to each class meeting Practice Problems, FAQs, Exam Reviews, Project Assignments are updated frequently Technology Microsoft...
Words: 2793 - Pages: 12
...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...
Words: 4633 - Pages: 19
...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...
Words: 2322 - Pages: 10
...Management Training Courses Accelerated. Modular. Experiential Operations Management Course Planning, building and managing enterprise operations Course Methods: Experiential workshop (action learning course) Course Venue: Las Vegas, Nevada, USA Course Duration: 4 days Course Time: 9AM-4PM Course Dates: Management Training Courses Calendar Course Fees: $3,999 | Option 2: Operations Management Courses Online: $995 Why IIM?: CEO Club | Training Excellence | Client Testimonials Course Audience: * COO's Team: Operations Managers, Procurement Managers, Supply Chain Managers, Production Managers, Manufacturing Managers, Warehousing Managers, Inventory Managers, Quality Managers, R&D Managers, Innovation Managers, Project Managers, Entrepreneurs, and Operations Management Consultants. Course Objectives: * Provides an understanding of operations management framework * Offers experiential analysis to understand the challenges of COOs and Operations Managers * Provides an understanding of the functions and practices of production and operation managers * Training topics include supply chain management, research and development (R&D), manufacturing, project management and quality management * Provides insights on how to develop strategies, initiatives and programs to introduce and sustain competitive operations in organizations * Focuses on lean six sigma best practices, tools and models to develop and...
Words: 1175 - Pages: 5
...Designing Lean Systems Video Case: Lean Systems at Autoliv Q1. Why is a visual management approach such an integral part of Autoliv’s lean system? Visual management is when a visual aid/device promotes more efficient and less wasteful processes. As mentioned in the text, a visual aid methodology that is commonly used is the Five S (5S). This method helps to organize, clean, develop, sustain, and sustaining a productive work environment (Krajewski, Ritzman, Malhotra, 2013). The 5S’s are: sort, straighten, shine, standardize, and sustain (Krajewski, Ritzman, Malhotra, 2013). The 5S practices enable workers to be able to see what they need to get done in a different manner, and can even provide a greater focus. Visual management is a big part of Autoliv’s system because they depend on each employee recognizing when there is a problem and correcting it as soon as possible, which helps eliminate waste. In a lean system, a business has to reorganize any process that creates waste or even eliminate it. So, each employee has different responsibilities, which has to be done in a certain time and also relies on the quality of the product. The visual communication method is to use a “rail” for the management of the heijunka cards in each cell. The rail has color-coded sections. These sections provide instant identification of cell status and can trigger escalation of that condition to management where appropriate. As each card is delivered, it slides down a color-coded railing...
Words: 2044 - Pages: 9
...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...
Words: 7223 - Pages: 29
