Home - New Zealand - Denmark - Fun Stuff - CV - Projects - DIY

1: Seiri, sort (Organize, remove unnecessary objects and reduce waste)

2: Seiton, set in order (put everything into its proper place)

3: Seiso, shiny clean (make a standard for cleanliness, it’s the only one-time step in 5S)

4: Seiketsu, standardized cleanup (the goal is 5 minutes cleaning per worker per shift)

5: Shitsuke, sustain (make a checklist and make the management “walk the talk”

TQM (Total Quality Management) What is quality and how do we meet the customer expectations. Quality means user satisfaction, that goods or services satisfy the needs and expectations of the user.

Six steps in CPI (Continuous Process Improvement):
1: Select the process to be studied.
2: Record the existing method and data in a usefull form.
3: Analyze the recorded data to generate alternative improved methods.
4: Evaluate the alternatives and develope the best method.
5: Install the method as standard practice by training the operator.
6: Maintain the new method.

The loop in PAC (production activity control). Plan-Implement-Manufacturing operations-Control. PAC is responsible for executing the master production schedule and the material requirements plan.

Muda, the seven wastes.

1: Transportation

2: Inventory

3: Motion

4: Waiting

5: Over-processing

6: Over-production

7: Defects

But also Latent skill is a waste.

MLT (Manufacturing Lead Time)

1: Queue time

2: Setup time

3: Run time

4: Wait time

5: Move time

Delivery lead time.

Four basic strategies:

Engineer to order.

Make to order.

Assemble to order.

Make to stock.

What are we going to make.

What does it take to make it.

What do we have.

What do we need.

Facts to record in the existing process.

The process boundaries. (Starting and ending points)

Process flow. (The steps between the starting ending point)

Process inputs and output.

Components (the resources used in changing inputs to outputs).

Customer. (Fulfil the customer needs)

Suppliers. (they can be internal and external)

Environment (the internal factors).

7 waste in production

1 transportation

2 Stock/inventory

3 overproduction/quality

4 over producing

5 scrap

6 movment of operator

7 waiting

8 over qualification

9 lack of communication

5 basic input.

1 Product description (Drawing-BOM)

2 Process specification (Rouling file/sheet,operations, sequence of operations, equipment, standard time)

3 Time needed for operations.

4 Available facilities.

5 quantity (order, forecast)

Six big losses:

1 Breakdown.

2 Setup and adjustments.

3 Small stops.

4 Reduced speed.

5 Startup rejects.

6 Production rejects.

A Gantt chart is a type of a bar chart, that illustrates a project schedule. It illustrates the start and the finish dates, for the elements of a project. The Gantt chart gives a good view over the work breakdown structure of the project

DMAIC in Six Sigma = Define.

Measure.

Analyze.

Improve.

Control.

RFID(Radio frequency identification) is an automatic identification technology, for tracking product and parts in a production line. A great help to minimize manual handling and find the exact lead-time

Quality cost concepts. There are two broad categories. 1: Cost of failure (internal/external failure cost) 2: Cost of controlling quality (prevention/appraisal cost)