Contributions by Application of Kaizen

Optimising Manpower

The excess manpower employed can be identified and optimized through proper load balance.

Reducing Work-in-process Inventory

1. Optimal stock of material for the process can be identified.
2. The lot size can be reduced to small.
3. Reconsideration of decisions regarding volume of finished product is possible.
4. Material handling can be reduced and hence rejections or reworking can be reduced.
5. Small and frequent, transport runs can be avoided

Quality can be Enhanced

1. A system can be built up that makes it easy to understand the causes.
2. Measures can be taken to stop the process immediately whenever defect occurs.

Enhancing Production Capacity

1. Providing simple and in-house developed machine to minimise manual work.
2. Finding out bottlenecks in process or machine.

Advantages due to Re-Layout

1. No delays in flow of material.
2. Possibility of better working space and condition.
3. Possibility of standardizing operations.
4. Quality built into to process.
5. Consideration on proper space for movement of trolleys, forklifts, etc.
6. Ability to realize flexible manpower line.
7. Attentive maintenance.
8. Safety and hygiene.

 Installation Visual Control on Line

1. Display of standard work sheet at the stations.
2. Pre-warning to the operators on approach.
3. Provides rhythm on the line.
4. Makes line supervisor alert regarding delays in operation.
5. Production control board - to display actual production figures on hourly basis and reason for short fall in planned schedule along with counter measure taken.