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Kaizen Event KNM Wave #6 Level 3 Master Training

Cleaning HUB Pilot Cell 2 7 & 8 February, 2007

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The Team TL: Peter Holtan Teammembers: Pavel urana Martin otkovsk

Jrgen Foessel
Nicola Martinis Tom OShea

Gerard de Fluiter

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Team Objective:
Clean, improve work environment & Safety in HUB Pilot Cell 2

Note: Second Lap Machine was down for maintenance.

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Why we did the KAIZEN (Preco sme robili KAIZEN)?

At the beginning of this activity we recognized that on the new cell we have already defined the procedures how to keep the order, etc. but these are not followed properly by us.

Na zaciatku tejto aktivity sme zistili, ze mame definovane procedury na dodrziavanie poriadku, udrzby atd. ale tieto nie su nami poriadne dodrziavane.

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Before we started:

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The Journey

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A little help from Rudi:

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After we finished:

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Suggestion 1: Mark with words which product needs to be here

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Suggestion 2: Replace fixed table with height adjustable table.

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THE 5-S AUDIT CHECKLIST

SCORE Department/Area

HUB pilot cell 2

Date

February 7 & 8, 2007

Person

P. Holtan

Before 1

After 2

SORT (SEIRI): Distinguishing between the needed and the not needed 0 1 2 3 4 5 No Activity has occurred. The criteria to determine the needed items has been determined. Needed items for the work area have been identified. There are no more than 8 violations of unneeded items present in work area. Initial red tagging exercise has been conducted and unneeded items have been removed. There are no more Than 6 violations of unneeded items present in the work area. A separate red tag holding area exists and an unneeded items log is posted in the plant. There are no more than 4 violations of unneeded items in the work area. Red tagging is performed at set time intervals, and the red tag holding area is evaluated at set time intervals. All items are reviewed regularly for need. There are no more than 2 violations of unneeded items. Only needed items ever enter the work area. There are no violations of unneeded items in the work area.

SET IN ORDER (SEITON): Organizing for ease of use, straightening up, and putting things away. 0 1 2 3 4 5 No Activity has occurred. All needed items are present, its not difficult to determine items in use. There are no more than 8 violations It is obvious where needed items (including tooling, tools, procedures, etc.) belong (using lines, labels, signs) There are no more than 6 set-in-order violations. The entire work area is visually indicated (including aisleways, workstations, equipment, storage locations, etc.) There are no more than 4 set-in-order violations. Items are put away immediately after use. It is easy to determine what items are in use. There are no more than 2 set-in-order violations. Height and quantity limits are visually obvious. There are no set-in-order violations.

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SHINE (SEISO): Sweeping, scrubbing, cleaning, and keeping things that way. 0 1 2 3 4 5 No Activity has occurred. Area cleaning is done randomly. There are no more than 8 cleanliness violations. Initial cleaning has occurred (floors, walls, stairs, surfaces). Machines and equipment have been cleaned. There are no more than 6 cleanliness violations. Cleaning/housekeeping responsibilities are documented and followed daily. Cleaning materials are easily accessible. There are no more than 4 cleanliness violations. Cleaning is used as an inspection tool for preventive maintenance. Cleanliness problems are found and preventive action is taken. There are no more than 2 cleanliness violations. The entire work area is spotless. Surgery could be performed in the area. There are no cleanliness violations.

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STANDARDIZE (SEIKETSU): Implementing procedures for the first 3-Ss and visual controls 0 1 2 3 4 5 No Activity has occurred. 5-S standards for conditions of Sort, Set in Order, and Shine have been set. Each of the first three Ss is rated 1 or higher. There are no more than 8 standardize violations. 5-S standards are documented and posted in work area using a workplace scan display or other visual method. Each of the first three Ss is rated 2 or higher. There are no more than 6 standardize violations. Needed items, Standard Work for 5-S, and Visual Controls are in the work area. Each of the first three Ss is rated 3 or higher. There are no more than 4 standardize violations. 5-S is measured and posted in work area. Each of the first three Ss is rated 4 or higher. There are no more than 2 standardize violations. 5-S documentation is routinely reevaluated and updated (including the workplace scan). Each of the first three Ss is rated 5. There are no standardizing violations.

SUSTAIN (SHITSUKE): Establishing the necessary discipline to consistently sustain 5-S standards. 0 1 2 3 4 5 No Activity has occurred 25% of employees in work area (on all shifts) have been trained in 5-S. Each of the first 4 Ss is rated 1 or higher. There are no more than 8 sustain violations. 50% of employees in work area (on all shifts) have been trained in 5-S. Each of the first 4 Ss is rated 2 or higher. There are no more than 6 sustain violations. All employees in work area (on all shifts) have been trained in 5-S. Each of the first 4 Ss is rated 3 or higher. There are no more than 4 sustain violations. All employees in work area perform daily and weekly 5-S activities as part of their standard work. Each of the first 4 Ss is rated 4 or higher. There are no more than 2 sustain violations. Area employees help create a planning worksheet to sustain 5-S standards and guidelines. 5-S activities are documented in each employees standard instructions. Each of the first 4 Ss is rated 5. No sustain violations.

5-S Total:

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Questions