process
consumable products. 25 per cent of his working days are non-value
adding!
By implementing Point of Use Storage we reduced his travel time by
nearly 85 per cent and freed up an extra 50 days of production at just
one work station. Imagine if we could do this at every work station?
We automatically have a 32 per cent gain in available processing or
manufacturing capacity, with no capital expenditure. Alternatively, this
could reduce the need for overtime hours.
4. Shine
The next step is to Shine the workplace. In Australia, this has become
synonymous with housekeeping, but it is far more than this. Personally,
I prefer the American version, Sweep, where the manager and staff
visually sweep the work area to identify any defects or items out of
place, and immediately address these issues.
5. Standardise
If you do not develop a system and support structure to support your
Lean Manufacturing program it will quickly lose momentum.
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6. Sustain
Fit
retro-fit double glazing, the
most advanced double glazing for existing
timber windows.
Reduce Energy Costs. Reduce Noise.
Retain Character. Add Value.
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We need to set standards for housekeeping, equipment maintenance,
material stock levels, teamwork, continuous improvement and the
accountability of operators, team leaders and managers in the
workplace. This is often where companies fail to lock in the gains as
this can be time intensive and requires culture change. Many managers
and business owners do not have the skills, patience or knowledge to
do this well.
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5S is only one of many tools that are used in the lean journey.
Personally, I prefer to review the flow of materials and information
in the workplace and get some quick wins using ‘Flow Kaizen’ Rapid
Improvement Events then lock in the gains with good 5S and ‘Visual
Workplace’ practices.
As each company we work with in the windows and doors sector has
a difference process and product profile, no one standard approach
can be taken. We would recommend a two day review process which
includes the development of an action plan, followed by activity based
training and Rapid Improvement Events to make a difference to your
operations.
360° protection
Please Note: Since this article was written, the author has been appointed
Director – Continuous Improvement with JELD-WEN Australia.
For more information on applying Lean Manufacturing in the windows and
doors sector, or government subsidised training in your workplace, contact
Glass Skills Australia on 1800 886 269 or [email protected]
01 A Lean Manufacuring workplace audit in progress.
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02 Point of Use Storage system.
Windows Magazine Winter 2016 29