Continuous Improvement Overview. The C.I. Focus. Cycle of Continuous Improvement. Standardize. Implement New Methods. Expose Problems. CI. Solve Problems. Continuous Improvement.
Cycle of Continuous Improvement
Implement New Methods
Continuous Improvement is an integral part of successful manufacturing in today’s competitive environment. It can help your company
Continuous Improvement is systematically
identifying and eliminating waste,
as quickly as possible, and at the lowest possible cost.
(Doing more with the same
Doing the same with less)
Continuous Improvement enforces working in-station, to standard operating procedures, as a key factor in achieving quality at the process.
During workshops, opportunities for simple quality confirmations are identified.
Participants learn to always consider the
impact to quality when making changes
to the process.
Bottleneck processes are individual processes or tasks that take more time than other processes and slow production. Continuous Improvement workshops
focus on waste
Being able to quickly identify and respond to abnormal conditions is critical to managing a manufacturing environment. Visual Management tools are improved to
Unstable processes are difficult to staff and manage and inherently create waste in the production environment. Identifying and reducing process fluctuation
We Gain Efficiency Through:
Process vs Results
Speaking with Data
A safe work environment is one of the cornerstones of a successful business.
Continuous Improvement supports the idea that no change should ever be made to a process that has a negative impact on safety!
There are quality standards and expectations demanded of any manufacturing product.
Changes to the process should never decrease the quality of the product provided to the customer!
The ergonomic impact of work should always be examined to see if improvements can be made.
Part presentation that places heavy or awkward parts within proper ergonomic levels
can decrease waste of motion and
Any changes to tools or processes
should be analyzed with a critical eye
towards any impact on ergonomics.
Lean Manufacturing focuses on the identification and elimination of the 7 forms of waste:
Team Leader - point of contact, organizes agenda and activity, orchestrates team activities, keeper of all documentation, also a team member
Team Members - contribute fully to the project, share knowledge and expertise, participate in all activities and discussions, carry out assignments
Facilitator/Advisor - provides technical or planning assistance, provides training, focuses on the team’s process (how) rather than product (what), works with team to eventually become self-reliant
Day 1: Assess the current condition
Develop improvement ideas
than 1-2 processes per team member
* Any required pre-training should be provided prior to workshop kick-off
Day 2: Simulate Changes
implementing process changes!
Day 3: Implement Improvements
changes are being made to help and answer
Day 4: Validate Impact
reductions in cycle times.
Day 5: Present Results
portion of the presentation
Section 1: Workshop location, team members, targets, etc.
Section 2: Initial condition
Section 3: Waste and opportunities identified
Section 4: Highlight improvements made to
Section 5: Results (before and after)
Section 6: Open items
Section 7: Next Steps
Reduced max cycle time in cell from 48 seconds to 42 seconds
Reduced total cell cycle time from 259 seconds to 221 seconds
Reduced manpower by 1 operator per shift
Increased cell utilization from 77.1% to 88.4%
other production lines or other
areas of the plant.
Improvement within your
Problems are Opportunities
Non-Judgmental / Non-Blaming