1st Edition

Kaizen Assembly Designing, Constructing, and Managing a Lean Assembly Line

By Chris A. Ortiz Copyright 2006
    260 Pages 122 B/W Illustrations
    by CRC Press

    It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation.

    Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them.

    Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.

    1
    Commitment to Change
    Chapter Summary
    2
    The Company Kaizen Program
    Kaizen
    Kaizen Events
    Kaizen Program
    Create and Communicate the Vision
    Establish the Kaizen Champion
    Communication Boards and Newsletters
    The Kaizen Governing Committee
    Kaizen Champion
    Plant Manager
    Production Manager
    Engineering Manager
    Materials Manager
    Quality Manager
    Facilities/Safety Manager
    Human Resources Manager
    Kaizen Team Selection
    Team Leader
    Team Members5
    Process Engineer
    Quality Engineer
    Facilities/Maintenance Personnel
    Materials Handler
    Line Operators
    Management
    Kaizen Event Tracking System
    Kaizen Tracking Worksheet
    Kaizen Event
    Team Leader
    Team Members
    Date and Length
    Strategic Purpose
    Anticipated Results
    Preplanning
    Estimated Cost
    Event Spending
    Actual Results
    Action Items
    Due Dates for Action Items
    Responsible
    Status
    Kaizen Monthly Meetings and the Kaizen Event Supply Box
    Kaizen Monthly Meeting
    Discussion of Open Action Items: 15 Minutes
    Discussion of the Last Event's Results: 20 Minutes
    Planning Upcoming Events: 30 Minutes
    Kaizen Event Supply Box
    Chapter Summary
    3
    The Basics
    The Seven Wastes, 5S, and Standard Work
    The Seven Wastes
    Overproduction
    Wait Time
    Transportation
    Overprocessing
    Inventory
    Motion
    Defects/Rejects
    The Eighth Waste
    5S
    Sort
    Straighten .
    Scrub/Shine
    Standardize
    Sustain
    Standard Work
    Chapter Summary
    4
    The Strategic Purpose
    Business Metrics
    Productivity
    Floor Space Reduction
    Work Station Reduction
    Travel Distance Reduction
    Quality
    Work in Process (WIP) and Inventory Reduction
    Effective Hours
    Product Volume
    Takt Time and Cycle Time
    Takt Time
    Cycle Time
    Visual Management
    Production Control Boards
    Weekly 5S Board
    Daily Quality Data
    Safety Board
    Daily Productivity Board
    Takt Monitors
    Chapter Summary
    Electric Bike - Kaizen Event Preparation
    5
    Four Weeks to Go
    Select the Area and the Kaizen Team Leader
    Order Supplies and Equipment
    Antifatigue Mats
    Lift Tables
    Tool Balancers or Retractors
    Metal Tubing
    Floor Tape and Laminating Material
    Labels
    Parts Racks
    Plastic Part Bins
    Workstation and Tower Lights
    Miscellaneous Preparation
    Time and Motion Studies
    Time and Motion Study Rules
    Use a Stopwatch
    Use a Time Study Collection Sheet
    Document the Tasks and Elements
    Capture Every Piece of Work Content
    Involve the Operator
    Conduct the Time Studies
    Capture at Least Eight Samples
    Time All Options
    Remove the Highest and Lowest Times and Take
    an Average
    Time to Begin the Kaizen Event
    Chapter Summary
    6
    Waste Analysis
    Current State
    Cycle Time versus Takt Time
    Equipment Constraints
    Changeover Time
    Material Optimization
    Waste
    Waste Observation of the Electric Bike Assembly
    Main Assembly Line
    Miscellaneous Value-Added and Nonvalue-Added
    Work
    Future State
    Chapter Summary
    7
    Two Weeks to Go
    Select the Kaizen Team Members
    Get an Update on Supplies and Equipment
    Miscellaneous Preparation
    Line Balancing
    Resource Requirements
    Eliminate Nonvalue-Added Work
    Balance by Time
    Balance by Work Content
    Balance by Material
    Chapter Summary.
    8
    One Week to Go
    Gather Current State Statistics
    Meet with the Team Members
    Miscellaneous Preparations .
    Standard Work Sheets
    Main Assembly
    Headlight Assembly
    Chapter Summary
    The Kaizen Event - The Electric Bike Line
    9
    Day One
    Kickoff Meeting
    Ground Rules
    Be on Time
    No Cell Phones or Pagers
    100% Dedication of the Team
    Eat Lunch as a Team
    Stay Positive
    Make Decisions and Stay on Schedule
    Let's Get to Work
    Red Tag Team
    Review of the Standard Work Sheets
    Lunch Break
    Midday Meeting
    Completing the Red Tag Event
    End of Day Meeting
    Chapter Summary
    10
    Day Two and Day Three Line Design
    Midday Meeting
    Assembly Line Construction
    Maintenance and Machine Shop Projects
    Tool and Part Presentation
    Tools57
    Tool Balancers
    Tool Stands
    Shadow Boards
    Parts
    The Two-Bin System
    Part Use in Containers
    Large Part Use Not in Containers
    Subassemblies
    Day Three
    Subassembly Work Cell
    Main Assembly Line
    Chapter Summary
    11
    Day Four
    Workstation Signs and Parts Rack Signs
    Floor Taping and Designations
    Two-Bin System Labels
    Color Labels.3
    Two-Bin System Assignments
    Subassembly Build Levels
    Installing Shadow Boards and Tower Lights
    Production Control Boards
    Takt Monitor
    Chapter Summary
    12
    The Final Day
    5S Audit Sheets
    5S Tracking Sheet
    Work Instructions
    Quality at the Source
    Employee Cross-Functional Matrix
    Rate Cards
    Standard Work for Three Different Rates
    Line and Operator Placement Map
    Standard Workbook
    Line Tour
    Chapter Summary
    13
    Training and Accountability
    Training
    Single Piece Flow (Push vs. Pull)
    Flexing
    Effective Hours
    Tower Light Use
    Two-Bin System
    Build Levels
    New Employee Training
    Product Overview
    Lean Basics
    Incentive and Pay for Skill
    Mock Line Training
    Accountability
    Daily Guidelines
    Ongoing Guidelines
    Chapter Summary4
    14
    Moving Forward
    More Kaizen
    Kaizen Event Ideas
    The Second Pass Kaizen Event
    Inventory Reduction Event
    Line Removal Event
    5S Event
    Line Design Event
    Material Handling Event
    Mistakeproofing.
    Product Design
    Eliminating Picking Errors
    Use of Fixtures or Jigs
    Visual Indicators
    Ergonomic Evaluations
    Chapter Summary
    15
    Coin Dispenser Manufacturer Success Story
    A10 Line Kaizen Event, Kaizen Team
    Day One
    Day Two
    Day Three
    Day Four
    Day Five Closeout
    Six Months Later
    Final Thoughts
    Glossary
    Index

    Biography

    Chris A. Ortiz