Stage 1 assignment

Men rocks Pvt. Ltd.

Designation: Process Engineer/ lean executive.
Assignment timings: 1 day.

Problem statement

Manufacturing process explanation

1) Bricks of different colors are being produced in the production floor.

2) Bricks to different colors in sorted format move to the quality checking tables for
checking by quality controllers.
3) Bricks then move on to primary packaging table wherein the bricks are packed in plastic
bags.
4) Then sorting is done.
5) Bricks of same color are to be packed inside one box.
6) Boxes are scanned and then sent for final dispatch.

** Number of manpower shown in the diagram is exact number of manpower available for
that process.

Tasks
1) Find the inefficiencies in the system and tag them to the different types of wastes as per
lean methodology.
2) Make PDCA.
3) Do the 5 why analysis to find root causes of such inefficiencies in the system.