Lean Manufacturing

Level 2
By
Hardeep Singh
 Contents

• Health and Safety

• Workplace organisation Techniques
• Week at workplace
• Communication & working effectively
• Work related Problem Solving
• Working Relationship and individual rights
and responsibilities
• Workshop
• Six Sigma
 Lean Manufacturing

Lean Manufacturing is a Methodology which focuses

on minimising waste,while working to maximising
the Productivity
 Health and safety

Health and safety is everyone’s

responsibility!!!
Health and safety ACT 1974
• It protects every one
• Outlines the responsibilities of employer and
employee
• It included welfare such as toilets, washrooms etc

Secondary Regulations:-
1. The workplace health and safety welfare regulation
1992
2. Manual handling operations regulations 1992
3. The Personal Protective equipment regulation 1992
4. Health and safety First Aid regulation 1981
 Health and safety

Assessment the employer needs to do:-

• Risk assessment
• COSHH Assessment Control Substance Hazardous Health
• Fire risk assessment
• First Aid Assessment
 Health and safety
Ways of managing risk:-
• PPE Personal Protective Equipment such as Hard Boots, Safety
Glasses
• Place notices, Signs at work place
• Conduct regular Staff training( First aid, Manual handling training)
• Use appropriate ventilation, Lights, noise levels
• Reporting of Lost time accidents(RIDDOR) Reporting of Injury
Diseases Dangerous Occurrence Regulations
Before and after Health and safety
 Workplace Organisation

Workplace organisation is organisation of people, material,

tools and Process.

Systems used :
• Work and waste analysis- Value Added and non Value Added
• 5S
• Visual management(Visual Display, visual control)
• Kaizen
• PDCA
 Work & waste
• Value Added is the Work that alters Nature, Shape and
characteristics of the product- Something the
Customer wants adding

• NON-Value Added is work that has to be done at the

moment to allow us to add Value

• Everything else is Waste- TIMWOOD

Transport
Inventory
Motion
Waiting
Over production
Over process
Defects
 5S & KPI
At JCB the key Performance Indicators used are
5S is a Methodology that results in 12

Clean, Uncluttered, safe and well • SAFETY

10
Number of near misses
• QUALITY
organised workplace to reduce waste
• DELIVERY 8
and increase Productivity • COST 6
• PEOPLE
• ENVIRONMENT 4

0
week 1 week 2 week 3 week 4 week 5

no of near misses Target

Right first time percentage

100
99
98
97
96
95
94
93
Monday Tuesday Wednesday Thursday Friday Saturday Sunday

Right First time Precentage Right First time Target

 Visual Display and Visual Control
Visual Display is sharing of information-
To display information on how is the
company doing, what company is doing
and also signs and labels of where things
are. For Example KPI to show how the
company is performing. Team
Safety
Team Board Photos
Cross
Visual Control Indicates abnormal conditions
Examples
•Operator not following Standardised Work
• Not wearing correct PPE
• Defect bins quickly filled up
•Too many empty spaces in a parts rack 5s
• Poor 5s Production Board footprints
Red
Tags
 Kaizen and PDCA
Kaizen means improvement in PDCA is other
Lean manufacturing it means methodology similar to
continuous improvement. It is a Kaizen. It standards for
• Plan
methodology which helps the
• DO
employees and employer to keep
• Check
doing incremental improvement
• ACT
to the system or process.

It helps to
• Lower Defects
• Eliminate waste
• Boost productivity
• Promote innovation
Example of before and after
 Week at Power systems
Day 1
• Induction of the Power systems
• Health and safety
• Manual Handling

Day 2
Worked at 10B
 Week at Power systems

Day 3& 4 worked at 150

Day 5 worked at 310

 Communication
Methods of communication

What to consider when communicating

verbally to others?

• Language
• Pace
• Tone
• Timing
 Communication
Punctuation matters

Punctuation matters!

Punctuation matters!!!!!!!
In the manufacturing scenario it is important to get technical
terminology right

Sources of technical information

• Job Instruction
• Standard Operating Procedure
• Engineering Drawing
• Material specification
 Communication

Outline the process for identifying and

resolving problems in manufacturing
environment
• Andons
• Area patrol
• 5Whys
• PCM- problem counter measure
• Production monitoring
 Communication
Forms of communication at
workplace
• One way communication
• Two way communication
• Internal
• External
• Upward
• Downward
• Horizontal
• Formal
• Informal
 Communication

Performance review

Feedback

Continuous personal development

Objectives

• Set SMART Targets

Specific, Measurable, Achievable, Realistic and
Timely
 Work Related Problems Solving
Different techniques to Identify the Examples of problems at Manufacturing
problem:- environment

• Questionnaire/Surveys • Delivery targets not met

• Histograms • Lack of material
• Live status Board • Cost to high (labour/Machine)
• Visual control tools-Andons • Defects
• KPI • Accidents
• PCM • Loss of customers/ Orders
• Suggestion Boards • Low Morale
• Team meting
• Bottle necks
 Work Related Problems

Clarify the problem by using Data. Data

Collection and analysing Data.
It is important to get correct data as it
helps to:
• Make a informed decision
• Identify issues
• Locate problems
• Gives you a strategic approach
• Shows progression or regression
• Shows patterns and Trends.
Use Ishikawa’s 7 Tools of Quality to record
analyse the Data
 Work Related Problems Solving

Locate and pinpoint the problem. Put containment

actions for the problem.

Use cause and effect diagram(fishbone diagram to find

all the causes for the problem

Find the root of the problem by 5 Why investigation

Put the counter measure in place to solve the
problem. Record the results. Use 8D sheet to
share with all departments and areas. Re-train
staff. Update any documents such as SOP’s, Job
instruction etc
 Work Related Problems Solving
Team needed to solve problem
Cross functional team.
Member of staff from different Departments.

Characteristic of Team member roles

• Leader-Performer
• Challenger
• Doer
• Thinker
• Supporter

Not needed and should be corrected

• Potential trouble source
• Destroyer
 Working Relationship and individual rights
and responsibilities

Positive Thinking Negative thinking

• Motivated • Demotivated
• Learner • It’s not worth it
• Adapts to change • Generally lazy
• Never give up/Quits • Ignorance
• Confident • Gives up easily
 Working Relationship and individual rights
and responsibilities
Benefits of Good working Why the team working is
relationship important?
• Improved Team working
• Improved Morale
• Strong problem Solving
• Retention of individuals
• Increased Productivity team
• Increased communication • Happier team/ Happier
individual
Common Problems • Lowers the risk of
• Communication burnout- Every one
• Money/Wage pulling in one direction
• Arguments • Boost productivity
• Micro manged
• Expands Creativity
Features of Good Team
• Capability
• Coaching
• Conditions
• Cooperation
• Cognitation
• Coordination
• Communication
 Working Relationship and individual rights
and responsibilities

Career Development
Achieve- Goals- Team leader-
• Apprenticeship
Group leader-Manager-Any
• Qualification
other Job target
• Industrial Placement
• Secondments
Set Goal-Yearly-monthly-Daily
• Appraisals/Review
Positive mindset- Never Give
• CPD
up
• In House training
• Shadowing
Hardworking + opportunity=Luck
• Attitude
Visualisation + intensity=Reality
 Working Relationship and individual rights
and responsibilities

Working Committee
Trade Union
• Employment Right Act 1996
• National minimum wage Act 1998
• Employment relation Act 1999
• The Maternity And parental Leave
regulation Act 1999
• Part time Workers Regulation Act
2000
• Transfer of Undertaking regulation
2006
• The Equality Act 2010
• Agency Workers Regulation Act 2010
 Workshop

In the Workshop exercises we did Nylon Block and

Dowel Extractor. We used the different skills we
learned from another units such as Health and
safety and workplace organisation
• Risk assessment of the work area
• Checking the equipment – emergency stop- flap
• Checking all the tools are safe to use
• Checking if the tools are in date
• Created 5S check list
Correct Personal protective required
• Safety glasses
• Hard boots
• Gloves if needed i/e using the Hacksaw

Health and safety at work act 1974 covers the

Health
and safety outlines the responsibilities of employer
and employees
Workshop
 Workshop
Process we used while conducting this exercise was
• The engineering Drawing
• The job instruction by the teacher
• Used the measuring gauge to measure all the measurements so it is accurate.
• Used File, Vice , compass, Hacksaw, go no go Gauge. Centre Punch
• Drill Machine, Drill Bits
• M10,M8 Hand tapper
• Dyenut

We learned techniques such as

• Filing the edges of the block.
• Working out the radius
• Filing the semi circle shape at the bottom of the block.
• Using radius to draw the circles on the block 6mm and 8mm
• Using hacksaw to saw Through the block
• Working out the hole size using a thread size
• How to create SOP
 Six Sigma
Six Sigma was developed to reduce Variations and
Defects.

Uses DMAIC or the DMADV method.

DMAIC
Define, Measure, Analyse, Improve, and Control
DMADV
Define, Measure, Analyse, Design, Verify

What is difference between Lean and Six Sigma?

In lean Waste is defined by process and activity

and
In Six sigma it is defined by variation in the process
and sigma.

Use Lean first to get rid of non value added

process then use six sigma to reduce variation in
value added process.
 Lean manufacturing
1. Lean manufacturing- Save time-Minimise non value essential
process-eliminate Waste. K4,S4

2. Health and safety- Laws-assessments-Managing risk-Signs,

PPE, Riddor, K1,S1

3. Workplace Organisation-Five 5, KPI,Work and waste ,Kaizen,

PDCA,K2,K9,K7,S2,S9,S7

4. Communication-Methods of communication- Punctuation-

Performance Reviews,K8,S5

5. Work related Problem Solving-Different techniques to find

problem-work related problem-locate problem and root cause
problem-5Why-Countremeasure-Team,K6,S6,

6. Working Relationship and individual rights and responsibilities-

Positive thinking-negative thinking-Career development-Goals-
UK employment Law-Workplace union, committee and
professional association

7. Workshop- Created Nylon Block-Dowel Extractor-Tools

used,K10,K11,K12,K13,K14,S10,S11,S12,S13,S14,S15

Behaviour KSB-B1 TO B11

My Experience at JCB Academy
Any Questions?