The document outlines a one-day Kaizen blitz event aimed at improving safety and housekeeping in a paint shop. Key actions included organizing trolleys, creating designated storage areas for high and low use trolleys, and cleaning the floor to enhance workflow and ensure clear fire exits. The improvements also included better signage and inventory management to maintain the changes in the workspace.

1. Kaizen Blitz: Paint Shop Layout
Alan Magner
Wednesday 27th July, 2011
Contact:
alanmagner@variancereduction.com

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. 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. 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. 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. 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