The document details a 1-day kaizen blitz event aimed at improving tool housekeeping on the Salvagnini machine in a sheet metal shop using 5S principles. Key outcomes included organized tool storage, reduced risk of damage, and enhancements in productivity and employee engagement. The initiative led to standardized storage solutions and encouraged similar improvements across other machines.

1. Kaizen Blitz:
5S on Salvagnini machine
Alan Magner
Monday 14th November, 2011
Contact:
alanmagner@variancereduction.com

2. • 1-day event to improve housekeeping at the Salvagnini in the Sheet Metal Shop
Agenda
 Improve the housekeeping of tools to improve productivity and reduce risk of damage to tools &
equipment
Target
 All tools have a designated place, and are kept in their place
 Reduced risk of damaged tools & equipment
 Reduced frustration across shifts
Results
 Nigel Welsh, John Shiu, Ariel Calderon, Dung Nguyen
Involved

3. Problem Statement
• Lost time searching for tools
• Risk of missing tools being left inside Salvagnini – possible
maintenance expense
• CLAs are expensive precision tools – risk of damage in storage
• Frustration in team across shifts – caused by poor
housekeeping
Before After
Action
• 1 day kaizen blitz to improve safety – using
5S principles to improve housekeeping and
employee engagement to sustain the
changes

4. Before: where are the tools?
Problem Statement
 Tools are stored in cabinet, no clear organisation of tools – takes time to find
 Tools have been left inside Salvagnini – poor housekeeping
Action
 Shadow boards attached to trolley – tools located at point-of-use, and efficient use of space
 Easy to see when all tools have been returned and not left inside machine
After: Shadow boards

5. Before: Precision Tools at risk of damage
Problem Statement
 CLAs are precision tools for inside Salvagnini – risk of damage when stored in tote bin
 Damaged CLAs can cause quality problems & machine performance
Action
 Standardised storage of all 8 CLAs to give each one a secure storage place
 Standardised storage of spot-welding consumables
After: Dedicated storage to protect CLAs

6. After: Space utilised well
Problem Statement
 Clutter removed from workspace – improved visuals for tool storage
 Tools stored at point of use – efficient for operators
Action
 Simple, quick, low-cost change
 Ideas have spread to other areas – Amada machine operators have designed own shadow boards –
standardised across 2 machines and 2 shifts
After: Tools labeled on shadow boards

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