Lean manufacturing examples

[2020ASJ]

this is one example of how to become lean "waste reduction".

Abdulwahab

[88bigstar]

Actually a very effective video showing WORKING lean basics and visual management systems. I have been implementing Lean/ Kaizen for over 12 years.....for those that think this is not Kaizen or Lean, sorry, but you really dont know what your talking about. Nice Job qualmen:D

[jplanelles]

Sorry, but this is not LEAN Manufacturing

[qualmen]

@jplanelles -- sorry but your opinion doesn't mean squat and apparently is much different than everyone else. When YOU post your own videos feel free to come back to the adult table to discuss it further. thanks for taking the time to review it though. please come again -- NOT.

[abrucelong]

Thanks for posting examples of great 5S and visual management approaches. This is very nice.

[jeremadman]

great job!

[thedemolisher86]

Sorry if I am overlooking anything, but with your component rack, how do you deliver these parts? Are withdrawal kanbans in place or do you just bring everything in house directly to the production line? Also noticed the skid of what appeared to be F/G bins partially labeled. I'm thinking that would be a concern for a mislabel to the customer. Just glad to see other approaches.

[Reubenhubert]

I understand the concept of saving time to make production more profitable,but how can anybody tell me how I should do my job if he has never seen how we do things? I am an R&D Modelshop Tech and we have to think on our feet and improvise.Our plant manager has never been in our work area while we were working,ever.We are doing a 5S now and it's a joke. Spraypaint,Stalling,Stupidity,­Spending and Shoving bad ideas down out throats. That's 5S as I see it.

[TheLeanIE]

I think these are poor examples of lean. I'm really shocked that someone posted this video when I have seen much better facilities.

[qualmen]

Well like the saying goes - opinions are like bungholes everyone has one and they all stink. When you post your world class video on Youtube then we can compare notes. Thanlks for taking the time to view it though.

[redtibby01]

have you implemented any poka-yoke systems in your plant?

[qualmen]

Many - we have done alot in the way of mistake proofing fixtures so components can't be inserted incorrectly and sensors to detect when they are missing altogether as well as many others.

[redtibby01]

that's great. not to many manufacturers know about this system. i have to say great job.

[OneHourDesign]

Love the Kiosk and the Visual Board at the end. Wondering what Blue and Yellow lines mean.

I'm a Black Belt and implementing Lean one step a time...some people dont like change.

[redtibby01]

we are implementing Lean where I work at a Regal Beloit plant. The blue and yellow line from what i believe is to separate fork truck path from work area, I think. We to have the yellow lines.

[gastonyt]

This looks like 5S or somthing.

Is lean manufacturing involving 100% use of visual aids..?

[srayatorres]

what type of metrics can I use to demostrate results?

Im not a lean manufacturing specialist but I know how can I work with 5´s and its an excellent rules..

[gtrain509]

this is great, thanks for showing examples of lean manuf.

[SweetStache]

I noticed around 1:25 you panned across a component rack containing the boxes of components to be used in the assembly area. Does you use an entire box of these components or how do you control the rate of use of these components in the assembly area?

I also liked the rotating kiosk for information and the 5-S was pretty good as well. Just wondering how you control the rate of production (the lockbox's purpose?--cannot build one until one is complete?) Just wondering...anywho - cool vid!

[qualmen]

The box itself in most cases is taken directly to the lineside storage with the exception of 4 components in the assy. The rate (TAKT) was determined as a result of customer requirements, available production time, and quoted number of personnel for the job. The lockbox was used whennever a line sensor detected a missing, misloaded component, which then requires a part to pass a sensor going down the lockbox entry gate before the stations will cycle again. Hope this answered your questions.

[thedemolisher86]

*Exploding Dap*

[jeromeyward]

I got a few ideas looking at this video for my next kaizen circle project at work. I work for a Honda supplier and am into kaizen and quality circles in a big way. Although our components (exhaust systems and door frames) would be too large for the "supermarket" approach, the revolving kiosk is a wonderful idea.

[qualmen]

I have also done some work through some 2nd Tier Honda suppliers in the Ohio area (near MArysville)...Glad they were usedful.

[jeromeyward]

Really? I work at Newman Technology in Mansfield, Ohio. We are a tier 1 supplier of exhaust systems, door frames, and door molding. We also make motorcycle frames and exhaust. I sent the url of your vids to your associate involvement coordinator and plant manager to look at.

[qualmen]

The irony --- I have actually been to your plant before. Years back I worked for Atlantic Tool and Die. I have gone for a number of years but have dealt with some of your QA folks. Good company there.. Good luck. --- Mark Netzel.

[vmp001]

ohh boy this vid was great, the american companies are the best, I have a question what is the diference between a Kaizen event and a Lean Man. implementation? they are related or are diferent things? thankyou for the advice, I have a last question, once I read a article from ishikawa where he said that all the problems on a company can be solved only by the implementation of the 7 statistical tools, hes concept is right? thanks a lot

[qualmen]

A kaizen event is an improvement event seeking to come up with improvements (safety, quality, productivity, etc). Lean Manuf is a very wide variety of tools and techniques. Look on Google. The 7 tools will allow you to fix many issues. I can't say it will allow you to fix every issue as there are other statistical tools that may be needed (D.O.E, etc) These can be used along with the 7 QC tools however. I am glad you liked the video.

[sbonacorsi]

Excellent and useful

Steven Bonacorsi

Lean Six Sigma Master Black Belt

[ajitsaini]

excellent