Lecture 7 - Introduction to Improve Flashcards
Discuss how improvements are made in company (x3)
- Generating Solutions
- Use Improvement tools
- Understand different solution types for selection
Name 3 Improvement tools
- 5S
- SMED
- Poka Yoke (Lean)
Improve - simple steps to take (x4)
- Creative thinking - idea generation.
- Prioritise for selection.
- Pilot Development - refine & finalise.
- Implementation programme - change/manage
Name 4 Generation tools
- Brainstorming
- Participatory groups
- Focus groups
- 5 -3- 5
Name 3 Selection tools
- Six thinking hats
- Evaluation grid
- Cost benefit analysis
Name 2 Development tools
- Prototype…….. Pilot
* Testing/Stress testing
Name 2 Implementation tools
- Change management
* Project management
Discuss Brain-storming (x4)
- Based on good understanding of group dynamic
- Don’t follow the rules (criticise while thinking)
- Less effective if over-used
- Equal contribution
Discuss P-I-T Method (x5)
5 People - 3 Ideas each - every 5 minutes
- generate group output
- Independent
- Time constrained
- Drawing/sketching/annotated output
P-I-T Method steps (x3)
- Everyone sketch 3 ideas
- pass your sheet to next person
- Then adapt, combine or new idea
Repeat till needed
5S Purpose and Objective
- create consistent outputs and maintain safe and clean working environment where people enjoy working
- support smooth flow of materials and information
What are the 5’s ?
Sort - (Clear Out)
Set - Order/Stabilise (Configure) layout /current / labelled / check list / ease of use
Shine - (Clean & Check)
Standardise - (Conformity)
Sustain - (custom & Practice) Audits / progress reports / update activities /
Why 5s?
- Create the best environment to reduce lead times and waste
* More efficient responsiveness
What is SMED
• SMED is the Single Minute Exchange of Die system
Single Minute means Single Digit minute up to 9.99 minutes
SMED Purpose
- Reduced in-process stock,
- Shorter lead time
- Just In Time supply of product
SMED Objectives
- Reduce the set up time BETWEEN stages of a process (ie handover of info/ material)
- Improve safety and productivity
SMED Steps
- One – Identify Pilot Area
- Two – Identify elements
- Three – Separate external elements
- Four – Convert internals into externals
- Five - Streamline remaining elements
SMED Step (Pilot area) (x5)
- Duration
- Variation
- Opportunities
- Familiarity
- Constraint
SMED Step (elements) (x4)
- Elements - parts to process
- Sticky Notes - process mapping
- Man & Machine - interactions
- Observe - video taping & observers
SMED Step (external) (x4)
- Retrieval - required things
- Inspection
- Cleaning - stand by tasks
- Quality - checking
SMED Step (Convert) (x4)
- Advance Preparation - pre work before processing
- Jigs - sort alignment and adjustments
- Modularize - replace component during maintenance (one on the run and one spare)
- Modify - guarding for cleaning
SMED Step (Streamline) (x7)
- Release - quick release mechanisms
- Adjustment - minimise needed adjustments (have saved settings)
- Motion - minimise
- Waiting - minimise
- Standardising - fewer options available
- Operations - parallel operations but needs thought having >1 person in area
• Mechanise - ?
Improvements types (3)
- quick win - human improvements
- medium effort - human tasks
- long term - technical improvements equipment/settings/design
Define Poka-Yoke (4)
• assure required quality of products with a minimum waste.
- identify critical to quality features
- develop and implement error proofing device
Basically it requires a ‘physical’ test that the components needs to pass through.
ie) square shape in circle hole.
Define Theory of Constraints (TOC) (1)
• constraint is any factor that limits the organisation from getting more of whatever it strives for
TOC Process - Five Step
- One – Identify the System Constraint
- Two – Decide How to Exploit the Constraint
- Three – Try altering Everything Else
- Four – Eliminate the Constraint
- Five - Return to Step One,… But beware of “Inertia
Increasing profit using TOC
• Maximise Throughput while Minimising Inventory and Operating Expense
2 types of Engineering
• Hard Engineering
Higher cost, semi rigid,
A higher level of skill is required
• SoftEngineering
Low cost, quick to install for trials.
Adjustments, even small ones can be easily carried out
De Bono’s Six Thinking Hats
- Questions (asks for everything that is needed)
- Thinking (thinking process)
- Bad points (devils advocate)
- Emotions (human factors)
- Creativity (adaptions)
- Good points judgement (optimist)
De Bono’s Thinking Grid
Option 1 – As a group go through each of the questions
•Option 2 – As an individual go through each of the questions
•Option 3 – As a group, assign hat roles, and have a discussion on each of the questions in your selected hat mode
