20 Keys to Workplace Improvement

Key 1: Key 2: Key 3: Key 4: Key 5: Key 6: Key 7: Key 8: Key 9: Key 10: Cleaning and Organizing Rationalizing the System/MBOs Improvement Team Activities Reducing Inventory (Shortening Lead Times) Quick Changeover Technology Manufacturing Value Analysis (Methods Improvement) Zero Monitor Manufacturing Coupled Manufacturing Maintaining Equipment Time Control and Commitment

Source: Iwao Kobayashi

20 Keys to Workplace Improvement

Key 11: Key 12: Key 13: Key 14: Key 15: Key 16: Key 17: Key 18: Key 19: Key 20: Quality Assurance System Developing Your Suppliers Eliminating Waste (Treasure Map) Empowering Workers to Make Improvements Skill Versatility and Cross Training Production Scheduling Efficiency Control Using Information Systems Conserving Energy and Materials Leading Technology and Site Technology

Iwao Kobayashi, Productivity Press

Key 1: Clean and Organize

Level 1 Cigarette butts, scraps of paper, and tools are scattered about Level 2 Clutters and piles of dirt lie against the walls Passageways are not cleared Unused items lean against walls Unused tools or equipment lie around Level 3 Walkways are clear and the factory is clean, but the storage areas are disorganized Cabinets are locked and contents mixed together Level 4 Machinery and equipment are clean

Key 1: Continued
Level 4 (continued) Storage areas are clearly distinguished, and show parallel lines and right angles Cabinets are unlocked Level 5 Everyone cleans regularly The work area is immaculate and tools are laid out squarely

Kobayashi: 271-2

Key 5: Quick Changeover Technology

Level 1 Current operating belief is that lot sizes should be large enough to reduce the number of changeovers Level 2 Some employees have received quick changeover training Setup time on all bottleneck equipment has been reduced by 90% Level 3 All manufacturing employees received quick changeover training Setup time on all processing equipment has been reduced by 90% Level 4 Setup time is reduced to under 10 minutes on all equipment Level 5 Changeover time is less than time required to produce 1 cycle (part)
Shingo, SMED; Kobayashi: 276