apo idro seminar-suzuki
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July '10, IDRO Seminar 0
Best Practiceof
Use-Warefor
Improving Factory Operation
Mr. Hajime SUZUKI (Dr. Practice)
Professional Engineer authorized by J apanese Government
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Guidelines* for
Practical KAIZEN
*by Dr. Practice
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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3. Practical Approach
4. Basics of Production Management
1) Effective Problem Finding
2) Effective Problem Solving 5. Integrated Activities
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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1) Critical Issue Oriented,not Tool oriented
2) Start from Pilot (Model) Area,not company-wide from the first
3) Practice Basics with Intensive Effortnot introducing sophisticated techniques/systems
3. Practical Approach
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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(1) Process Analysis
(2) Stratification
(3) 3 Gen ③find Fact (Genjitsu)
②by closely observing Actual thing (Genbutsu) ①at Site (Genba)
(4) 3 Mu ①Muda (waste) ②Mura (un-even: low and high in defect, etc.) ③Muri (un-natural, such as stacking too high, etc.)
4. Basics
1) Effective Problem Finding
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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In addition to the above
S (Safety) and
M (Morale) should be examined.
Production (capacity)
Material
Product
Machine
Delivery
Supply
Process
Quality (check and control)
Cost (waste of material & man, etc.)
Delivery (waiting time, etc.)
Order
Planning,Scheduling
(1) Process Analysis
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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1) Pareto diagram
2) Cause & effect diagram
3) Histogram
4) Check sheet
5) Scatter diagram
6) Stratification
7) Control chart and Graph
Ordinary 7 QC Tools Practical “ 8 QC Tools”
(in the order of effective use)
1. Stratification
2. Check sheet
4. Histogram
5. Pareto diagram
6. Cause & effect d iagram
7. Scatter d iagram
3. Graphs
8. Control chart
(2) Stratification
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Genba (at Site):
1. Manufacturing Ind.
Painting process, Assembly line, Inspection station,
Material stockyard, Production floor, Product warehouse,Maintenance store, etc.
2. Non-Manufacturing Ind.
1) Restaurant: Guest dining room, Kitchen, etc.
2) Shop: Showroom, Sales floor, etc.
3) Transportation: Road, Station, Truck, Warehouse, etc.
'3 Gen'-1 (Genba, Genbutsu, Genjitsu)
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Genbutsu (Actual thing):1. Manufacturing Ind.
- Good Quality product,
- Rejected parts,
- Work instruct ion in Foreign language,
- Semi-product covered with dust, etc.
2. Non-Manufacturing Ind. 1) Restaurant: - Table wares,
- Foods,- Materials ,
- Cooking utensils , etc.
2) Shop: - Best selling goods (design/color combination),
- Showcase, etc.
'3 Gen'-2 (Genba, Genbutsu, Genjitsu)
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Genji tsu (Fact):
- Semi-product covered with dust
Why with dust? - - staying 3 months
Why staying so long?
- - order was cancelled after producedWhy cancelled after produced?
- - this customer often gives uncertain order
Why started production without confirming order
- - followed general rule 'start as early as possible'
Why followed general rule?
- - there is no special rule for this kind of
non-reliable customer
'3 Gen'-3 (Genba, Genbutsu, Genjitsu)
Link: Pipe Plant
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Muda : Waste
1) Waste of material- Defective products,
- Start-up waste,
- Design waste,
- Dead stock,
- Long staying stock. etc.
2) Waste of manpower - Idle time,
- Over time,- Reworking, etc.
3) Waste of facili ty- Broken facility,
- Excess facility, etc.
'3Mu-1' (Muda, Mura, Muri)
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Mura : Un-even
Data:
1) Daily production very high and very low
2) Defects very low and very highOperaton:
3) Driving very fast and very slow
4) Materials coming too much and too little
5) Machines stop frequently
etc.
'3Mu-2' (Muda, Mura, Muri)
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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If 4Ms are good (normal),
No defect will come out.
Good Methods
Good
Machines and
Conditions
Good Men
(Operators)
Good
MaterialsNo
Defect
(1) Best Conditions
Do your
Best !
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Delivery : Delivery in Time
Finished Product : No Long Staying/Dead stock
Production
Material : No Long Staying/Dead stock
:Well control led WIP Final process
・ ・
1st process
(2) Flow Production
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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(3) Visual Control
① For Management “Visual Report”for managers to easily see important points by highlighting with red color, etc.
② For Shop-floor Control “In-process (or in-line) Visual Control”for operators
to easily follow work standard
③ For Shop-floor MotivationVisual Control posted on boards at shop-floor
Link : Case Machine (Visual Control-1)
Link : Visual Control 2
Link : Visual Control 3
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Plan,action Plan
2nd Target
Plan,action Plan*1
1st Target
(4) PDCA-2 (for Achieving Target)
Action*2
Check
Action=Helping to achieve target
*2: and Appreciation
Plan=Target for improvement *1: and Preparation
Do=Improvement activitiesIn Do step, we have small (p)(d)(c)(a)
Check=Progress of improvement
Check
Do(a) (c)
(p) (d)
Do (a) (c)
(p) (d)
Action
*2
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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PlanExisting level
(4) PDCA-1 (for Daily Operation)
Do=Daily operation
PlanBetter level
Act ionDo
Check
Higher level
Plan=Existing system & method
Check=Result such as customer
claim, reject, late delivery, etc.
Action=Improve system & method
Act ion
ActionDo
Check
Action
Link : Case ISO Aplication.
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Case Study 1
Best Practice
after
3-day Course
and
Small-scale Consultation
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Best ParticipantIn Suzuki's 'Practical IE' Course
Large variety of cushions for outdoor furniture exported to
many European countries.
Link: Case Co. B
Top Mgt of Co. B attended
Suzuki’s IE course, then
Suzuki v isited Co. B and
gave guidelines on how to
apply (Use-Ware).
She digested all what
Suzuki gave, then applied
them practically (developedher own Use-Ware).
The case is prepared separately.
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Practical 5S
5S with Kaizendeveloped through
Suzuki’s 20 years experiences
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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In Japan,・ 5S has been practiced for many years as common sense as Seiri
Seiton「整頓整理」 for Safety, Quality, Efficiency then Environment.
・ In 1986, 1st book on 5S was published, since then 5S rapidly
became popular.
・ In good companies, it has been continuously practiced and
keeping high level.
History of 5S
In many countries,
・ 5S was successful during the initial period, however after a
while, it easily become superficial, cosmetic and non-useful due
to wrong application.
In Iran,
- How is the situation?
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Ordinary 5S
Good for initial stage,but needs some modification for Practical use.
Seiri(整理): Sort out necessary items and un-necessary items, thendiscard un-necessary items.
Seiton(整頓): Arrange necessary items in good order so that theycan be easily picked up for use.
Seiketsu(清潔): Maintain high standard of Seiri, Seiton, Seiso andworkplace organization at all times.
Shituke(躾): Train people to follow good housekeeping disciplineautonomously.
Seiso (清掃): Clean the workplace completely so that there is
no dust on floor, machines or equipment.
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Objective
EffectiveProblemSolving
•Best
Conditions
•Flow
Production
•Visual
Control
•PDCA
PQCDSM
•Production
capacity
•Quality
•Cost
•Delivery
•Safety
•Morale
•Customer
Satisfaction
•Internal
Effectiveness
and Safety
•Profit•Happy
Life
5S
•Seiri
•Seiton
•Seiso
•Seiketsu
•Shitsuke
5S with Kaizen: always think Objectives
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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1. 1st stage: Ordinary 5S
Key point of Practical 5S
2. 2nd stage: Practical 5SPractice by thinking ” the objective of 5S at
each work place” for Effective Problem Solving,namely,
1) Best Conditions 2) Flow Production3) Visual Control4) PDCA
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Practical Seiri:
Sort out and remove un-necessary items and
from the workplace.
What is the key point here ?
⇒Clear ‘Criterion’ and ‘Instruction’
Practical 5S: Modified by SUZUKI -1
“quantity (of necessary items)”
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Practical Seiton:
Arrange - - for easy use (Location, Arrangement, Indication)
also must be
in
“ good conditions” (ready for use)
in “ fail safe ” (no chance of misuse,
preventing any accident)
Practical 5S: Modified by SUZUKI -2
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Practical Seiso:
Clean - - or equipment. Do it by considering the objective,
1) “ collect dust without scattering”
for clean workplace,
2) “ remove dust without damaging product ”
for sensitive product,
3) “ check and correct abnormal conditions”for machines and equipment.
Practical 5S: Modified by SUZUKI -3
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Practical Shitsuke:
No modification, but for newly established factory ,
Rules, Regulations and Work Standards come first).
Practical Seiketsu:
“Prevent from becoming dirty ”
and keep high level cleanliness
“ Maintain good hygiene”
Practical 5S: Modified by SUZUKI -4
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Case Study 2
Best Practice
after
3-day Course x 2 times
and6 times Consultation
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Best ParticipantIn Suzuki's ‘Practical 5S' Course
When I showed this picture.Mr. A said ‘we are muchhigher level, I don’t needthis’ and left the class with
nothing.
On the other hand Mr. D, owner of apparel company, attended 2 times inthe same course. He worked with Suzukias model company and achieved goodresult. He went to Japan as an excellentparticipants. He cooperated in sharinghis experiences in Practical 5S Course.
He was expectingwhat looks like this.
Link: Case Appael 2Link: Case Appael 1
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July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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Positive Mind
With your
Positive Mind, Your dream will
come true !
Please surpriseme with your
practice !
July '10, IDRO Seminar USE-WARE, Practical KAIZEN
Prefesional Eng'r, Hajime SUZUKI
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