1. Organize the work place
Only keep what is required in the work place. Have a designated place for every thing. Time should not be wasted in searching for things. The time to complete a work will be minimum when the work place is organized.
2. Develop quick setups for machines.
Use SMED methodology and develop quick setup times for each machine. Lot sizes can be made small and unnecessary cost incurred in maintaining inventories is saved by the company. Inventory has no function when setup costs are very low.
3. Eliminate transportation loss
Treat transportation as a waste. Place machines as close as possible and reduce transportation. This does not mean the work place has to be cramped. Do rational decision making.
4. Develop fixtures with one touch placement and automatic ejection
Minimize time of loading and unloading work pieces in fixtures or machines.
5. Introduce multiprocess handling
Train operators in handling machines that perform different processes and utilize them to handle multiple processes which are in sequence or closeby.
6. Synchronize processes
Don't install machines with unequal production rates. Create production lines having machines with similar production rates.
7. Use transfer lot size of one
Let operators hand over one piece across
8. Introduce Jidoka concept.
Make machine intelligent to stop automatically if there is a problem.
9. Introduce Poka Yoke and Statistical Quality Control
Poka Yoke will alert operators in case an error is committed and operators rectify. SQC allows operators to recognize the problem in the machine setup as early as possible with least cost.
10. Eliminate machine troubles
Once machine indicates a problem, use collective knowledge to eliminate the problem as fast as possible and also do root cause analysis and eliminate the problem at the root level.
11. Determine Cycle Time and Take steps to reduce it.
12. Standardize work procedures
Standardize means plan and create written procedure which is followed by everybody using doing that task. In continuous improvement paradigm, the procedure is improved. But it is also captured in the written practice and then only implemented.
New Manufacturing Challenge: Techniques for Continuous Improvement
By Kiyoshi Suzaki