You Are Here : Solutions Continuous Improvement Solution

The highlights of the solution.

Safety is a technical pillar that involves continuous improvement of working environment and reduction of factors generating accidents and dangerous occurrences. The aim of SAFETY pillar is to eliminate accidents. It requires more intense preventive actions, continuous improvement of ergonomics in the workplace and skills and qualifications necessary to eliminate potential hazardous events and accidents.

Despite many preventive measures taken there are always situations when customers are not satisfied with our products or services. This reflects the importance of this pillar. Defects are found and the cost of rejected products becomes a considerable expense for the company. This pillar is generally designed to provide customers with high quality products at minimal cost, to develop proper operating conditions for production systems and to increase quality problem solving skills of staff members.
Large stocks or a necessity to reschedule production due to raw material shortages are usually the reason for performing tasks being a part of this element of WCM concepts. The aim is to create favourable conditions for the flow of materials within the company and between the suppliers and the plant, reduce inventory level, minimize the amount of displacement, reduce the number of kilometres and transit time inside the company and from direct suppliers, integrated purchase, production and sales network.
The purpose of this pillar is to eliminate major waste identified previously within the Cost Deployment pillar. This way organizations do not exploit resources for problematic issues of minor priority. Corrective actions are targeted and have to lead to a final problem solving and restore or introduce a new, specific standard. This work should be carried out periodically because of its unique nature. The aim of this pillar is to achieve waste reduction in the production system and eliminate activities not generating value added and therefore not likely to increase the cost competitiveness of the product.

Organization of working place is one of the basic technical lynchpins of production in the world class manufacturing (WCM).Workplace Organization focuses on elimination of losses due to NVAA, Unbalance and Human Errors.

    Main activities of Workplace Organization are :
  • Reach cost deployment objectives by eliminating NVAA losses
  • Establish a culture against Muri, Mura, Muda
  • Design the workstation considering motion economy principles, obtain work safety and deploy improvements.
  • The Key indicators of Workplace Organization include Improvement in Productivity, Reduction of Human Error and Reduction of Non-Value Added Activities

MURI

Muri means non-ergonomic work – excessive bending, turning, reclining, moving arms up or down, kneeling, lifting, carrying, and also work monotony, that is everything that causes speedy tiredness of the worker while performing his duties. Analysing and Eliminating is so called Muri.

MURA

Mura is a Japanese word meaning "unevenness; irregularity; lack of uniformity; non uniformity; inequality”.The below form is used to maintain information about Plant, Department, Zone, Machine, Tool Number, Operator, process Steps, Name, Shifts, and Timing Intervals. Based on the timing intervals entered “Bell Curve” will be generated.

MUDA

Muda is a japanese word meaning uselessness, wastefulness.This mainly focuses on Analysis of losses.

The core concept of Muda involves “Seven Wastes” namely,Overproduction, Transportation, Waiting, Over-Processing, Defects, Motion, Inventory.

As machinery and equipment often operate in poor conditions and never work at full capacity this pillar becomes really important. The aim of this pillar is to improve the efficiency of the global production system by x. Restoration of a mechanical device or equipment to its original state and maintaining its initial technical parameters to prevent deterioration, x Increased involvement of production staff and development of a co-operation system favourable for both machine operators and maintenance service staff, x Development of technical skills and qualifications. All above mentioned activities must be supported by skills development. Furthermore, this pillar is also responsible for the proper organization of the workplace (Workplace Organization), efficiency improvement and getting the productivity of the production system up.
Scope of activities associated with this pillar is a result of the number of failures that occur in many systems, lack of systematic preventive measures and poor co-operation between machine operators and the maintenance service staff. Main activities under this pillar focus on: control and failure cause analysis, further qualifications of maintenance service staff, collaboration with staff members responsible for Autonomous Maintenance, etc.
Activities within this pillar are to ensure, through a structured system of training, appropriate skills and qualifications for every job position. In addition, maintenance service staff and technicians are prepared to train later other employees. There should be also knowledge and operational skills documentation system in place.
Manufacturer, as part of COST DEPLOYMENT pillar, for company's management analysis/audit has to introduce an effective plan of waste reduction where such activities can bring substantial benefits. It is necessary to develop an improvement program that will lead to a reduction of waste. There are activities carried out in order to identify waste, determine the place of their production, valuate them, identify elimination methods and expected results.
The tenth pillar is used to meet the environmental management requirements (compliance with the requirements and standards of the environmental management), continuous improvement of the working environment, etc. The main activities include: periodic internal audits verifying the impact of the plant on the surrounding environment, risk identification and prevention, use of ISO 14000 standard and a variety of technical improvements such as production site improvements.