5S, Heijunka & Lean Replenishment at SP Packaging,Satara · Solutions Kaizen Management Systems...

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Solutions Kaizen Management Systems Page 1 5S, Heijunka & Lean Replenishment at SP Packaging,Satara Problem Statement: Unbalanced production resulting in Delivery On Time of 50% . Also Huge Inventory is piled up occupying production area and money is stuck up. Action Plan: Sr No Activity Description Duration 1 Diagnostic Study 1 month 2 5S Training & 1S Kaizen Blast 1 month 3 2S – Paper Layout Finalization 1 Month 4 Layout Deployment 1 Month 5 Lean Replenishment Systems 4 Months 6 Heijunka Deployment 3 Months 7 Monthly Audit & Production Watch for sustenance 1 Months 5S Activities & Results: Training to Workers & Red Tagging Activities: Team Red Tagging the unwanted Material Training & Motivating the Actual Work Force

Transcript of 5S, Heijunka & Lean Replenishment at SP Packaging,Satara · Solutions Kaizen Management Systems...

Page 1: 5S, Heijunka & Lean Replenishment at SP Packaging,Satara · Solutions Kaizen Management Systems Page 1 5S, Heijunka & Lean Replenishment at SP Packaging,Satara Problem Statement:

Solutions Kaizen Management Systems Page 1

5S, Heijunka & Lean Replenishment at SP Packaging,Satara

Problem Statement:

Unbalanced production resulting in Delivery On Time of 50% . Also Huge Inventory is piled up occupying

production area and money is stuck up.

Action Plan:

Sr

No

Activ i ty Descr ip t ion Durat ion

1 D i agnost i c Study 1 month

2 5S T ra i n i ng & 1S Kai zen Blast 1 month

3 2S – Paper Layout F i nal i zat i on 1 M onth

4 Layout Depl oyment 1 M onth

5 Lean Repleni shment Sys tems 4 M onths

6 Hei junka Depl oyment 3 M onths

7 M onthl y Audi t & P roduct i on Watch fo r sus tenance 1 M onths

5S Activities & Results:

Training to Workers & Red Tagging Activities:

Team Red Tagging the unwanted Material

Training & Motivating the Actual Work

Force

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Implementation of 5S:

The machines were surrounded by the WIP material stacks.

There was no accountability for same.

Before State

After State

Machines were proper aligned with reduced stack of Materials.

WIP was reduced with reducing the batch size and proper Lay

outing

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Lean Replenishment System:

Due to huge Inventory of WIP/ Raw Material & FG Stocks the Production area was occupied and

money was stuck.

TheMin and max stock levels were defined and complete visible & Count Free Stores was established.

This helped to reduce the inventory by 40%

The Paper Rolls (Raw Material) was stocked in an un organised

manner. This resulted in damage to the paper and hence it was

wasted. (Approximate Monetary loss Rs.30000/-) There was no

accountability to the stock. So double buying was done.

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After State:

Following Improvements were done:

Pallets were used to store Rolls – This made material movement easy and reduced damage to

paper.

Min & Max Stock Levels – The min & max stock levels were defined & this helped to reduce the

Inventory.

Due to proper storage Counting & Stock Taking was easy activity,

There was complete visibility to stores.

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Heijunka System:

Job Card was designed explaining the Customer Order Requirement after the receipt of order. This job card is used to

track the material at each stage of material. After Completion of Order it is returned back to PPC.

Following Weekly Plan Display Board was established for visual Planning & balancing the Production

Morning & Sunset Meetings started to discuss Plan & actual Production.

Due to Fix plan for 1 week based on Customer’s Requirement the DOT was improved.

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A few Benefits achieved:

Sr. No Measure Before After

1. Productivity 100 tones/month 150 tones/month

2. DOT (Delivery On Time) 50% 80%

3. Lead Time 2 Days 1 Day

4. WIP 4 lacs 1-1.5 lacs

5. Inventory 1.5 crores 1 crore

6. FG Stock 35 lacs 27 lacs

7. Scrap Visibilty to scrap per m/c

8. Profitability Rise in gross profit by 15%

9. Fatigue High Very Less

10. Rejections Not Identified Now identified &

reduced

11. Floor Space Utilization 50 % 90 %

12. Stress Level High Very Less

13. Pride in Organization Less Very High