2 📈 Mudas Elimination

Through the study of waste-free solutions, all waste is eliminated or reduced. In this phase, each activity around the production line and workstation is analyzed with the Lean filter of the mudas, and through an intensive value-driven problem-solving activity, improvement solutions are found and built.

3 📈 New Standard Work Preparation

All the solutions for waste elimination are transformed into new standard work for each workstation. Every standard worksheet must be organized with a structure that facilitates comprehension at first sight and chunked-in learning bites to facilitate progressive learning.

4 📈 Production Line Transformation

All the workstations are revised and transformed to be adequate for the new standard work. Every needed device, furniture, and tool needs to be built with the operators or in tight collaboration with them, if necessary, with the help of third-party maintenance and artisans.

5 📈 Logistics System Transformation 

Warehouses are transformed into supermarkets, from which logistic loops pull components and raw materials. Your logistic crew and, eventually, third-party artisans must learn lean logistics concepts.

6 📈 People training

People are trained to work according to the new standards. Operator trainers must build the new skills matrix required by the new balancing workstation flow and develop and execute the training program for the production line operators and the logistic team. 

7 📈 New Production Line Start-Up

The new production line has started, and with the assistance of the trained supervisors, it will achieve the planned productivity target through intensive fine-tuning between operators and physical means helped by the team that participates in the productivity increase project.

8 📈 New Production Line Defect Elimination

After the new production line starts, an intensive check of what is working and what is not is performed, and definitive solutions are applied through problem-solving activities. When the production line stabilizes its increased productivity, it will be time to start a new PDCA cycle.

This process is fully developed inside the Productivity +30 program; if you want to know more, click the link below:

https://www.kaizen-coach.com/en/lean-consulting-for-the-mechanical-industry/how-to-get-more-productivity-from-production-lines-2

 

Mario Mason

(Kaizen Coach)

PS: If you need further information, send me a message.

Kaizen Coach
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