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Compare and Contrast for
Continuous Improvement
IEE 5200 – Modern Industrial Practices
Instructor – Dr. Tycho Fredericks
Submitted by – Sagar Sable
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?
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
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.
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.
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.
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
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.
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.
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
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.
Modern Industrial Practices Project

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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.