Applying lean-based tools and principles for processes evaluation and improvement.
My role in the project:
• Critically analyzed lean implementation effort like 5s, KPI of Wild flavors. Assessed.
• Used KPI’s to track the progress of operation and gathered data to identify opportunity like revision of VSM.
• Achievement:
A vast scope of improvement was observed at the facility especially emphasizing on the Quality Control Department (QC).
Modelling Guide for Timber Structures - FPInnovations
Modern Industrial Practices Project
1. Compare and Contrast for
Continuous Improvement
IEE 5200 – Modern Industrial Practices
Instructor – Dr. Tycho Fredericks
Submitted by – Sagar Sable
2. Outlines – Continuous Improvement
1. Tools and Techniques:
• What tool they using?
• Advantages and benefits of these tools?
• On going CIO project ?
2. Impact of Lean Culture:
• The changes occurred after implementation of CIO projects?
• How often they change and modify the process?
3. Training and Skill Improvement:
• When and how often they train their employees?
• How much CIO concepts are practices and in what area?
3. Fabri-Kal
1. Tools and Techniques:
• 5S, Kanban, root-cause analysis.
2. Impact on Lean Culture:
• Productivity increased with 10% every year.
• Runtime percentage, quality runs increases.
3. Training and Skill Improvement:
• Training employees to gain maximum productivity
• Increased customer satisfaction in terms of Quality
4. Steelcase
1. Tools and Techniques:
• 5s,VSM, Plan-Do-check-Act (PDCA)
• PokaYoke(Mistake Proofing), Hiejunka(Mix Modeling).
2. Impact of Lean Culture:
• Help to bridge between system demand and system inventory.
3. Training and Skill Improvement:
• Reduction in manufacturing cost by 1 million previous year .
• Increased customer satisfaction in terms of on-time-delivery.
5. LG chemical Inc.
1. Tools and Techniques:
• Use of 6 sigma Quality improvement technique.
• Injury rate reduction. Using OSHA technique.
• 5s,Kainzen, root-cause analysis.
2. Impact of Lean Culture:
• Efficiency of Quality product production reached to 99.4% .
• Battery quality and life increased .
3. Training and Skill Improvement:
• Increased customer satisfaction in terms of Quality.
• Periodic safety training sessions.
6. Lyon’s Industries
1. Tools and Techniques:
• 5s manufacturing system.
• Jidoka automation technique.
2. Impact of Lean Culture:
• Productivity increased by implementing robotic arms.
• 20 % increase in production and demand.
3. Training and Skill Improvement:
• Training employees every month rather than quarterly to gain
maximum productivity.
• Increased customer satisfaction in terms of Quality by taking
surveys.
7. Schupan & Sons Inc.
1. Tools and Techniques:
• Use of Kanban inventory management system and JIT
• Using ERP to track demands and orders
2. Impact of Lean Culture:
• Order completion and delivery on time.
• Efficient Demand management .
3. Training and Skill Improvement:
• Training employees about recycling techniques
8. Allnex
1. Tools and Techniques:
• They track unintended release of materials to the environment.
2. Impact of Lean Culture:
• Goal to reduce all unanticipated emissions to the environment
by 10%, year-on-year.
• In 2015, the number of releases to the environment greater
than one pound of material was 4, versus 12 in 2013.
3. Training and Skill Improvement:
• Monitoring both leading and lagging indicators, dedicated risk
assessments, gap analysis, training, peer review of
environmental process hazards, and capital investments.
9. Bell’s
1. Tools and Techniques:
• Kaizen and KPI (Key performance Index).
• Increased profits and
2. Impact of Lean Culture:
• Productivity is increased (800 barrel)
• Building new Logistic and fermentation center.
3. Training and Skill Improvement:
• CIO concepts are used to increase productivity in Bell’s
• Improving productivity, Efficiency and Quality.
10. Knoll
1. Tools and Techniques:
• 5s, Pull system, VSM,TQM
• Gemba walk everyday morning to improvement In plans.
2. Impact of Lean Culture:
• Improvement in delivery time and quality of product.
3. Training and Skill Improvement:
• The goal is to encourage teamwork, set ergonomic
guidelines, plan for new technologies or reinvent the office
11. A.C. Foundry
1. Tools and Techniques:
• Implemented Standard Work Procedures.
• Design of Experiment panel cards are used.
2. Impact of Lean culture:
• Optimize waste, efficiencies and reduces the cost.
3. Training and skill improvement:
• Green belt six sigma training is provided to the employees.