Lean

Lean Recommendations

Design Flow Process:

a. Balance Workstation Capacities - Organize a work area plan configuration system by setting up synchronized production personnel based on the nature of tasks. Example; Assign competent operators to critical areas (Machine 1- Milling Station, Sub – Assembly Area and Packaging Area) in the Production flow.

b. Redesign layout for process flows - Based on the Gizmos Production Flow, Most of the skids are far off from each other causing wait times for processing. Repositioning of the skids are necessary to improve production times and decrease waiting periods on succeeding related skids.

c. Emphasize preventive maintenance - Employ planned and scheduled maintenance activities regarding workers training, machine knowledge etc., to develop first time production of consistent and uniform products.

Total Quality Control:

1. Workers Responsibility

2. Measure SQC

3. Enforce Compliance

Stabilize Scheduling:

a. Level Schedule - Ensure uniform shifts

b. Underutilize Capacity - During idle periods, personnel or plant workers can be put to work on other activities such as special projects, work group activities and workstation house keeping

c. Establish Free Windows -

Kanbans System Recommendation:

Instituting a Kanban System with the production area will allow smoother production and better transitioning of products to the other parts of the manufacturing process. Below is a summary of the formula, computation and assumptions for the company:

Assumptions:

Average Demand per month = 150 per month or 12.5 demand per day

Safety Stock = 25% of the inventory

Container/Skid = 20

Work with Vendors:

a. Reduce lead times - Negotiate with the suppliers effective and efficient delivery schedules of raw materials and packaging materials.

b. Project Usage Requirements – Know the precise project usage specification of raw materials and packaging materials per batch...