The document outlines 13 steps to improve manufacturing systems through lean principles. The steps include implementing 5S, kaizen, one-piece flow, kanban, quality planning, visual controls, total productive maintenance, jidoka, standard work, leveling, a multi-skilled workforce, manpower reduction, and using success factors like coaching, KPIs, and rewards.

1. Manufacturing Systems The Steps to Success

2. Step 1 - Implement the 5 S’s Prepare a Training Package Appoint and Train area 5 S’s Champions Launch the 5 S’s Train All Employees Audit Progress Recognise and Publicise Achievements Reward Performance and Achievement

3. Step 2 - Implement Kaizen Prepare a Training Package Appoint and Train an overall Champion Launch Kaizen Train All Employees Establish a Kaizen Room Audit Progress Recognise and Publicise Achievements Reward Performance and Achievement

4. Step 3 - Map the Business Processes Map All Business Processes using Process Charts

5. Step 4 - Implement One Piece Flow Layout the Factory according to the Process Flow Work towards One Piece Flow

6. Step 5 - Implement Kanban Work towards EDI-ban

7. Step 6 - Implement Advance Quality Planning Implement Quality Function Deployment Perform Risk Analysis using FMEA Implement Process Control Plans Establish and Improve Process Capability using SPC Establish the use of the Seven Quality Tools

8. Step 7 - Implement Visual Control Make the Flow Visual Use Visual Indicators to highlight Danger Areas, Work Areas and Walkways Implement Location Indicators Implement Quantity and Height Indicators Implement Andon Lights

9. The Steps to TPM Prepare a Training Package Appoint and Train an overall Champion Launch TPM Train All Employees Audit Progress Recognise and Publicise Achievements Reward Performance and Achievement Step 8 - Implement Total Productive Maintenance

10. The Steps to TPM Implement TPM on All Critical Machines/Equipment Appraise Condition of Equipment (Ensure Availability of Manuals) Restore Equipment to “As New” Condition Determine Operator Tasks (Autonomous Maintenance) Implement Preventative Maintenance

11. The Steps to TPM Establish “Front Line” Spares Policy Implement Predictive Maintenance (Condition Monitoring) Implement Quality Maintenance Implement Reliability Centred Maintenance Implement Improvement Maintenance (6 Big Losses)

12. Step 9 - Implement Jidoka Create a Culture of Stop and Fix Build Poka Yoke into the Processes Convert Human Work to Machine Work

13. Step 10 - Implement Standard Work Create Standard Operating Procedures for all Business Processes

14. Step 11 - Implement Leveling Focus on Large Variations between Process Cycle Times Focus on High Transport Time and/or Distances Focus on Equipment and Machine Breakdowns

15. Step 12 - Establish a Multi-Skilled Workforce Determine the Processes Rate each Persons Competency Against each Process Establish Critical Mass Requirements Create a Skills Matrix Create Training Modules Train to Meet Critical Mass Requirements

16. Step 13 - Implement Manpower Reduction Remove Excess Manpower from All Processes Remove Excess Manpower resulting from Kaizen activity or “Break-through” Management

17. Key Success Factors Coaching and Mentoring Encouragement Key Performance Indicators Visible Change Publicising Successes Rewarding Achievers