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Kaizen Blitz Projects line packing Aug 2011

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Kaizen Blitz Projects line packing Aug 2011

  1. 1. Kaizen Blitz: Projects Line Packing Alan Magner Thursday 25th August, 2011 Contact: alanmagner@variancereduction.com
  2. 2. • 1-day event to improve safety & housekeeping in the Projects Line packing area Agenda  Improve the housekeeping at the Projects so the walkways will always be kept clear Target  Walkways are kept clear  All pallets have a designated place, and are kept in their place Results  Maria Santa, Borka Todorovic, Disco, Zhi Hui Zhu Involved
  3. 3. Problem Statement Walkway for people & forklifts was restricted by trolleys and by pallets of 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 Before After
  4. 4. Before: no access to racks Problem Statement  pallets of cardboard for packing are blocking racks of inventory  Future plan to remove racks – new location needed for cardboard Action  Re-located safety bollards – cardboard now closer to point-of-use – cardboard pallets have a dedicated place After: Storage for cardboard inventory
  5. 5. After: Dedicated place for finished goods Problem Statement  Pallets of finished produced faster than can be collected by warehouse  Not enough space for pallets of finished goods Action  Dedicated place for finished goods (6 pallets) – location supports future process changes  Dedicated place for empty pallets (8 pallets) After: Dedicated place for empty pallets
  6. 6. Before: Space not utilised well Problem Statement  Limited space at end of projects line  Large numbers of pallets (cardboard, finished goods, empty pallets) – all need a location Action  Simple, quick, low-cost change  No compromise in safety standards by moving bollards  Inventory closer to point-of-use After: Dedicated place for finished goods
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