BackStreet Lean: Solutions for the Job Shop, Plant Edition
Through the successful application of Lean in the job shop, a group of world-class plants share their best practices and numerous photos from their shops.
TABLE OF CONTENTS BackStreet Lean: Solutions for the Job Shop, Plant Edition
Phase 3: Sustaining the Lean Process
Overview
Section Overview
Moving Lean practices into the whole organization is the focus of Phase 3. Lean initiatives already in place are sustained, the entire plant is redesigned, and processes are implemented and monitored to identify and eliminate waste.
| Critical First Action | Redesign the entire plant in a cellular format by creating theoretical models of the plant floor and cell layouts. The models are designed by a broad cross-section of personnel and implemented over time as company resources become available. |
| Critical First Action | Striving for zero set-ups is a continuous effort to shorten set-up time until it is low enough that it does not affect the cost of the part. |
Gain process control by examining and defining the processes of an entire operation from start to finish, and identify ways the process can be continuously improved. A common mistake is to focus on an end product which is defective, and change only enough of the process to fix the problem. This creates an acceptable end product with a short-term fix, which is only a band-aid for the problem.
Create a scheduler to use as a tool for communicating job status and work flow on a cell-by-cell basis. The scheduler can be electronic or a manual board and is accessible throughout the plant.
Developing a tool crib eliminates the need for cell operators to be responsible for tools or pieces of work holding. A tool crib attendant supplies needed equipment in a timely manner to operators,...
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