Kaizen Assembly Designing, Constructing, and Managing a Lean Assembly Line

It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation. Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them. Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.

1Commitment to Change Chapter Summary2The Company Kaizen Program KaizenKaizen Events Kaizen ProgramCreate and Communicate the Vision Establish the Kaizen ChampionCommunication Boards and NewslettersThe Kaizen Governing Committee Kaizen Champion Plant Manager Production ManagerEngineering ManagerMaterials ManagerQuality ManagerFacilities/Safety Manager Human Resources ManagerKaizen Team SelectionTeam Leader Team Members5Process Engineer Quality Engineer Facilities/Maintenance Personnel Materials Handler Line OperatorsManagement Kaizen Event Tracking System Kaizen Tracking Worksheet Kaizen EventTeam LeaderTeam Members Date and LengthStrategic Purpose Anticipated ResultsPreplanningEstimated CostEvent Spending Actual ResultsAction ItemsDue Dates for Action ItemsResponsible StatusKaizen Monthly Meetings and the Kaizen Event Supply BoxKaizen Monthly MeetingDiscussion of Open Action Items: 15 MinutesDiscussion of the Last Event's Results: 20 MinutesPlanning Upcoming Events: 30 MinutesKaizen Event Supply BoxChapter Summary3The Basics The Seven Wastes, 5S, and Standard Work The Seven Wastes Overproduction Wait TimeTransportationOverprocessingInventory MotionDefects/Rejects The Eighth Waste5S SortStraighten .Scrub/Shine Standardize SustainStandard Work Chapter Summary4The Strategic PurposeBusiness Metrics Productivity Floor Space Reduction Work Station ReductionTravel Distance Reduction QualityWork in Process (WIP) and Inventory ReductionEffective Hours Product VolumeTakt Time and Cycle Time Takt TimeCycle TimeVisual ManagementProduction Control BoardsWeekly 5S Board Daily Quality DataSafety BoardDaily Productivity BoardTakt MonitorsChapter SummaryElectric Bike - Kaizen Event Preparation5Four Weeks to Go Select the Area and the Kaizen Team LeaderOrder Supplies and EquipmentAntifatigue Mats Lift TablesTool Balancers or Retractors Metal Tubing Floor Tape and Laminating Material LabelsParts RacksPlastic Part Bins Workstation and Tower LightsMiscellaneous PreparationTime and Motion StudiesTime and Motion Study Rules Use a StopwatchUse a Time Study Collection SheetDocument the Tasks and ElementsCapture Every Piece of Work Content Involve the Operator Conduct the Time Studies Capture at Least Eight Samples Time All OptionsRemove the Highest and Lowest Times and Takean AverageTime to Begin the Kaizen Event Chapter Summary6Waste Analysis Current State Cycle Time versus Takt TimeEquipment ConstraintsChangeover TimeMaterial Optimization Waste Waste Observation of the Electric Bike Assembly Main Assembly LineMiscellaneous Value-Added and Nonvalue-AddedWork Future State Chapter Summary7Two Weeks to Go Select the Kaizen Team MembersGet an Update on Supplies and Equipment Miscellaneous PreparationLine Balancing Resource RequirementsEliminate Nonvalue-Added WorkBalance by TimeBalance by Work Content Balance by Material Chapter Summary. 8One Week to Go Gather Current State Statistics Meet with the Team Members Miscellaneous Preparations . Standard Work Sheets Main AssemblyHeadlight Assembly Chapter SummaryThe Kaizen Event - The Electric Bike Line9Day One Kickoff Meeting Ground RulesBe on Time No Cell Phones or Pagers 100% Dedication of the TeamEat Lunch as a TeamStay Positive Make Decisions and Stay on Schedule Let's Get to Work Red Tag TeamReview of the Standard Work SheetsLunch Break Midday MeetingCompleting the Red Tag EventEnd of Day Meeting Chapter Summary10Day Two and Day Three Line Design Midday MeetingAssembly Line ConstructionMaintenance and Machine Shop Projects Tool and Part Presentation Tools57Tool Balancers Tool Stands Shadow BoardsPartsThe Two-Bin System Part Use in Containers Large Part Use Not in ContainersSubassemblies Day Three Subassembly Work CellMain Assembly LineChapter Summary11Day Four Workstation Signs and Parts Rack SignsFloor Taping and DesignationsTwo-Bin System Labels Color Labels.3Two-Bin System Assignments Subassembly Build Levels Installing Shadow Boards and Tower Lights Production Control BoardsTakt MonitorChapter Summary12The Final Day 5S Audit Sheets5S Tracking Sheet Work InstructionsQuality at the Source Employee Cross-Functional MatrixRate Cards Standard Work for Three Different Rates Line and Operator Placement MapStandard Workbook Line TourChapter Summary13Training and Accountability Training Single Piece Flow (Push vs. Pull) Flexing Effective Hours Tower Light UseTwo-Bin System Build LevelsNew Employee Training Product Overview Lean BasicsIncentive and Pay for SkillMock Line Training AccountabilityDaily Guidelines Ongoing Guidelines Chapter Summary414Moving ForwardMore KaizenKaizen Event Ideas The Second Pass Kaizen Event Inventory Reduction Event Line Removal Event5S Event Line Design EventMaterial Handling Event Mistakeproofing. Product DesignEliminating Picking ErrorsUse of Fixtures or JigsVisual Indicators Ergonomic Evaluations Chapter Summary15Coin Dispenser Manufacturer Success Story A10 Line Kaizen Event, Kaizen Team Day One Day Two Day ThreeDay Four Day Five Closeout Six Months LaterFinal ThoughtsGlossary Index