INSIDE MANUFACTURING®
©February, 2000 Dennis Mellersh Editor and Publisher
Tel: (416) 754-4454 Fax: (416) 291-6830 e-mail: acgm@sympatico.ca
The lean machine
Manufacturing veteran Tony Spoore notes
that in lean manufacturing the focus is on
eliminating waste in every area of production
as well as other areas such as customer
relations, product design and the supply
chain. The goal of lean is to reduce human
effort, inventory, product-development time
and space requirements. Overall aim: to be
responsive to customer needs while
producing as high a level of quality as is
economically possible. Many companies start
this process by conducting a “Quick Lean
Assessment”. (QLA)
5S and QS 9000 compliance
One of the challenges in implementing QS
9000 is establishing the measurable, or
auditable, company-wide continuous
improvement (CI) component which this
standard requires. Anders Nielsen offers a
ready-made solution – 5S. The five basic
manufacturing disciplines (5S) consist of
working continuously toward an organized,
lean, and standardized working environment
in all parts of the company. It does this
through a self-imposed standard, which
means the results can be measured and
evaluated objectively. If you are looking for a
way to comply with QS 9000 without having
to invent a measurable CI program, give 5S a
try.
Seeing is believing
In today’s time-critical, lean-oriented plants,
traditional spreadsheet methods can be
inadequate for accurately predicting
outcomes in process flow analysis (PFA). By
using computer simulation as a PFA
enhancement, however, the elements of
variation observed in the real world, such as
time, can be introduced. A “what if” scenario
can be viewed as reality on
the computer screen including overall work
movement, bottlenecks and blocked work
centers. Ideas can be tested in minutes
without the need for expensive set-up tests.
And there is no need to disrupt production.
What is 5S?
The components of 5S are: separate,
simplify, sanitize, systems, and standardize.
Five “S” words, thus 5S. 5S will set up a
step-by-step system that creates a safe, clean
and productive working environment. 5S can
be a good foundation for ISO/QS. Other
benefits can include: reduced cycle times,
increased floor space, standard operating
procedures, improved material flow, better
communications, improved set-up times,
reduced search time, reduced inventory costs
and improved delivery times.
Mature set-up reduction
Set-up reduction must be viewed as an
ongoing or continuous process, says
manufacturing specialist Len Jacobs. Initial
reductions, considered “quick kills,” are the
easiest to achieve and often require no capital
investment. As the set-up is reduced, the need
for capital equipment increases. The
problems most common to set-ups requiring
capital investment are: clamping,
disconnecting, high tool weight, tool
placement and tool retrieval, storage and
handling. In assembly operations most of the
time lost in changeover is in material search
and confusion. Evidence includes unmarked
containers with no storage space allocated
and idle labor unaware of the problem.
Kitting in common returnable containers can
help solve these problems. Detailing the set-
up routing for employees eliminates the
confusion and lost time.
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Executive Briefings
Some of our readers have expressed an
interest in attending half-a-day executive
briefings on a variety of factory floor
improvement subjects, particularly 5S Quick
Programs and Set-Up Reduction Programs.
Please check the fax coupon if you would
like more information on executive briefings.
On the firing line
Promoting an untrained operator or other
worker to a supervisory position without
providing proper training is like trying to fly
a jet aircraft without rudder controls. Both
the supervisor and the plane will crash. The
tasks of the front-line supervisor are
demanding: higher productivity, improved
quality and lower costs. The front line
supervisor must juggle the requirement of
“getting the job done” with factors such as
policies, procedures and the often conflicting
needs of management, workers, customers
and possibly contractors. Hands-on, non-
“academic” training is needed. A good start
to meeting these requirements is through a
Basic Front Line Supervisory Training
Program. Topics should include:
Fax Request Form: If you would like further information please complete this
form and fax to: Tony Spoore (416) 421-3017
q The lean machine (QLA)
q Five S (5S) & QS compliance
q Process flow analysis (PFA)
q What is 5S (Five S)
q Mature set-up reduction
getting the job under control, time
management, overcoming the problems of
“being in charge,” and basic work planning
to achieve desired results.
Mature set-up checklist
If you have had a set-up reduction program
in place for some time, there is a danger it
will run out of steam. Continued success
requires written procedures, measurement,
setting new targets, modifications and
practice, among other factors. Inside
Manufacturing has a 10-point checklist to
help determine if your set-up teams are on-
track. Please indicate on the fax coupon if
you would like a copy.
Housekeeping tips
Workplace organization is essential if the
plant floor is to replace the stockroom. The
stockroom mentality must be created on the
floor so that parts can be moved smoothly in
the small-lot production environment. Stock
points must be organized so the location of
each part is specified by number in a marked
spot. The same is true for set-up tools. Quick
set-up can only be achieved if there is a place
for everything and everything is in its place.
This discipline is the responsibility of the
operators and supervisors.
q Executive Briefings
q On the firing line
q Mature Check list
q Housekeeping tips
q Other…………………………….

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