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Kaizen Blitz Paint shop layout Jul 2011

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Kaizen Blitz: Paint Shop Layout
Alan Magner

Wednesday 27th July, 2011
Contact:
alanmagner@variancereduction.com

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Agenda
1-day event to improve safety & housekeeping in the paint shop

Target
 Improve the housekeeping at the Paint Shop...

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Before

After

Problem Statement
Access to the fire exit at the Paint Shop was blocked by trolleys and by inventory
Action...

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Kaizen Blitz Paint shop layout Jul 2011

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Kaizen Blitz Paint shop layout - changing the layout to improve safety and workflow
Do we try to change people's behaviours, our should we change the situation? A change in the physical work environment can allow the desired behaviours to happen without resistance

Kaizen Blitz Paint shop layout - changing the layout to improve safety and workflow
Do we try to change people's behaviours, our should we change the situation? A change in the physical work environment can allow the desired behaviours to happen without resistance

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Kaizen Blitz Paint shop layout Jul 2011

  1. 1. Kaizen Blitz: Paint Shop Layout Alan Magner Wednesday 27th July, 2011 Contact: alanmagner@variancereduction.com
  2. 2. Agenda 1-day event to improve safety & housekeeping in the paint shop Target  Improve the housekeeping at the Paint Shop so the Fire Exit will always be kept clear Involved  Mick Norton, Steve Cowling, Mohammed Riyaz Results  Fire Exit is kept clear  Reduced walking distance looking for trolleys, and moving trolleys out of the way  All trolleys have a designated place, and are kept in their place
  3. 3. Before After Problem Statement Access to the fire exit at the Paint Shop was blocked by trolleys and by inventory Action 1 day kaizen blitz to improve safety – using 5S principles to improve housekeeping and improved workflow, and employee engagement to sustain the changes
  4. 4. After: Storage for empty disc trolleys After: Storage for empty trolleys Problem Statement  Paint shop has 20 trolleys – not enough room to store them Action  Made storage area for 8 disc trolleys that is 5m from the paint shop – used for trolleys with the low use  Made storage area in the paint shop for 6 empty trolleys that have high usage
  5. 5. After: Storage for painted product After: Improved visuals & signs Problem Statement  When large discs are painted need space to store them – need a space where product won’t be accidently touched or bumped Action  Made storage area for 1 trolley that is 3m from the paint shop – only used for trolleys with painted product  Improved visuals - Signs labelling each storage area
  6. 6. Before: Residue and dirt on floor After: Place for inventory to be chromated Problem Statement  When picked parts are delivered to the paint shop for chromating, there is no dedicated place for them  Floor was dirty Action  Allocated an inventory square for parts to be delivered to. Enough space between square & chromating baths to allow easy transfer, pallet “off-square” to allow for a straight drive-in & drop for forklift drivers  Paint shop floor was swept & mopped, dirt & residue was removed

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