Layout Kaizen
Design a layout in such a way that it is flexible and can be changed to respond to changes in process flow. Layout that can make the job easier and safer for the worker removes drudgery from operator's job and makes more productive. Layout Kaizen should focus to assure ease and safety in
- Flow of objects
- Flow of people
- Flow of information.
How to do?
After a decision is taken to change the layout, a full scale card-board cut out has to be made for each machine/equipment. As per changed layout, these cut outs can be laid out in a vacant space so that any interference to man or material besides maintainability can be foreseen. Layout can be changed in any idle shift or off days without hampering production. Attention must be paid to following points while conducting Layout Kaizen :
- Possibility of standardizing operations.
- Safety and hygiene of operators.
- Delays in flow and counter flow of material.
- Flexible manpower planning.
- Built in process quality.
- Maintainability of equipment and machines.
- No bottlenecks to housekeeping, proper collection of chips and their disposals.
- Prevent flying of chips using chips guards.
- Flexible hydraulic hoses and electrical cables between machine and panels.
- Use of single piece conveyors between the machines, wherever required and no trolleys, tables, etc. for keeping Work in Process (WIP).