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Study Report: Observations
Study Report: Observations
Study Report: Observations
Observations:
There is lag in production planning like to know the status of working
progress, Daily & Monthly production planning & Inputs like materials, men
and machines are efficiently used, Production control, Planning plant capacity
for future production, production schedules, grouping similar products /
process, Lead time, To avoid / reduce the scrap generation.
Have to develop production activities such as studying about cycle time of
process / machine / man, need clean & standardized shop floor, Labor
productivity, Utilization of equipment and space, Continuous improvement,
process Capability, to set benchmark, work instructions
Have to improve the activities in Quality such as line inspection, First off &
Last off report, Determine what parameter is to be controlled or critical ones,
Cost of Quality as well as cost of poor quality, Customer satisfaction, supplier
monitoring & Rating, Most importantly usage of 7QC Tools
Have to develop the Design & Development activities like detail drawings,
process drawings / stage drawings, control plan, Bill of material in respective
drawings itself, developments of tools, process & Gauges, analysis of failure.
5S
Lean Manufacturing
7 QC Tools
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Solutions:
5S:
Why we need to maintain 5S ?
Remove unnecessary items and dispose them properly, Make work easy by
eliminating obstacles, Provide no chance of being disturbed with unnecessary
items, Prevent accumulation of unnecessary items
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Prevent loss and waste of time, Easy to find and pick up necessary items,
Ensure first-come-first-serve basis, and Make work flow smooth and easy.
Gives identification to tools, gauges, conformance & Non conformance
areas.
Lean manufacturing :
Why we need to implement Lean Manufacturing ?
We can use this tools / methodologies to aim for the continuous elimination of all
waste in the production process. The main benefits of this are lower production
costs, increased output and shorter production lead times.
Defects and wastage Have to Reduce the defects and unnecessary physical
wastage, including excess use of raw material inputs, preventable defects, costs
associated
with
reprocessing
defective
items,
and
unnecessary
product
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process or feature which is not required for creating value from the customers
perspective is waste and should be eliminated.
2. Standard processes Need to implementation of very detailed production
guidelines, called Standard Work, which clearly state the content, sequence,
timing and outcome of all actions by workers. This eliminates variation in the
way that workers perform their tasks.
3. Continuous flow we have to aims for the implementation of a continuous
production flow free of bottlenecks, interruption, detours, backflows or waiting.
When this is successfully implemented, the production cycle time can be
reduced by as much.
4. Pull-production this is need ed to produce only what is needed, when it is
needed. Production is pulled by the downstream workstation so that each
workstation should only produce what is requested by the next workstation.
5. Quality at the Source this is one of the important and basic one for
defects to be eliminated at the source and for quality inspection to be done by
the workers as part of the in-line production process.
6. Continuous improvement To improve our
perfection by continually
removing layers of waste as they are uncovered. This in turn requires a high
level of worker involvement in the continuous improvement process.
Over production
Waiting
Work In Progress (WIP)
Transportation
Inappropriate processing
Excess motion or ergonomic problems
Defected products
Underutilization of employees
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Time Study
Target Setting
Waste identification
Machine cycle
Implement Kaizen
Man cycle
Non Cyclic
inspection
Implement Cyclic
Motion with single piece
Target Achieved
check measurable
Standardized work
chart material Flow
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7QC Tools:
Why we need to use 7QC Tools:
7QC Tools gives the clear datas, Graphical representative to understand
easier as well as to form the grouping, Most importantly to find in which areas of
process / product most of rejection / reworks happening based on this we can
take corrective / preventive action with helpful of Cause & Effect diagram or
Failure Mode and Effects Analysis, To get the relation between two things by
Scatter diagram or Characteristic Matrix and to determine the variation we can
use Control chat.
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