function write5S()
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"5S
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5S is often the foundation stone for any improvement project as it puts in place a basic stability in the workplace.
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Sort - What is needed from what is not. Red tag those items which don't have a home and put them in a quarantine area where they can be evaluated. After a set time then they are disposed of by selling, given away, or stored according to frequency of use. If needed every day then POUS (Point of Use Storage), if once a month then out of the way of production but somewhere it can be located when needed.
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Set in Order - Identify the best location for items, set inventory levels and paint lines showing the flow of work and a place for everything.
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Shine - Clean everything, inside and out and inspect as you go along. Machine faults are often found this way.
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Standardise - Make the rules for maintaining the first three S's until they become habits
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Sustain - Discipline, training, communication to make sure the 5S's aren't going to go away. Expect 15% or more improvement in productivity just by putting this in place. Don't you just love the idea already?
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function writeSummary()
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"Many companies need to change and improve the way they do business if they are to distinguish themselves from the competition and make a profit."+
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We specialise in short to medium term on-site facilitation while training can be given in-house or off-site depending on your company’s needs. "+
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Our consultants and associates are greatly experienced and have managed change with the attendant unavoidable problems in actual production areas and projects, so they can clearly recognise your situation and your needs."+
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Manufacturing Solutions can provide the customised help through Lean Manufacturing that will ensure the company receives the best solution for them. Lean manufacturing is an umbrella term for a range of improvement tools including 5S system, SMED or quick changeover, Cellular or Flow Manufacture. Pull/Kanban, TPM and Visual Factory."+
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Before you buy that new machine to alleviate that bottleneck, take on more staff, move to bigger more expensive premises or build that new layout, call on us, as invariably we may be able to suggest a lower cost solution."+
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As a simple rule of thumb, if it’s costing a lot of money, if you are being offered a so called 'Software solution', then it’s not Lean."+
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Use the contact page to email your name and contact number and we will arrange a visit at your convenience.";
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function writeCellular()
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"Cellular
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Once the 5S system is in place the layout is often the next place to start the next improvements. Value Stream Mapping of the current layout helps expose the wastes and then a future state map is drawn up. Once the first area to be improved is identified then a Kaizen event can be organised to 'Blitz' the area which can result in moving the machines and assembly processes into 'U' shaped Cells to enhance one-piece flow. This has the effect of reducing lead time by up to 90%, improving productivity by up to 30% and reducing space used by up to 50%. WIP (Work in Progress) is also reduced by up to 90% and quality faults by up to 85%. Feedback on quality problems is almost immediate which reduces rework and scrap. Apart from that there is still a good argument for Mass Production. (not!)
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function writeKanban()
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"Kanban
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Kanban is the Japanese name for a card that travels in a package with parts. Legend has it that it was used by downstream workers to make sure they got the right parts by sending it to the stores with the request. It was taken up as a good idea and expanded to actual boxes, stillages etc which contain a certain number of parts and are used as a signal to the upstream supply operation. Often a two bin system is used to make sure that the downstream operation does not run out of parts and in this way parts required are 'Pulled' from the supplying process.";
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function writeSMED()
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"SMED
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SMED is Single Minute Exchange of Die, invented by Shiego Shingo at Mazda Hiroshima it is a lean tool for reducing machine changeover time. The single is for single digit or less than ten minute changeover and is a very effective way of reducing the perceived need for large batches through machines.";
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function writeTPM()
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var textString=
"TPM (Total Productive Maintenance)
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Once you have all the building blocks in place then those companies that have a lot of machines can really benefit from TPM. It is a way of monitoring how effective your machines are and OEE (Overall Equipment Effectiveness) measures Quality, Performance and Availibility to come up with a percentage that really separates the men from the boys. While it is not a cure all for every factory it is one of the most valuable tools in the box for the Lean Practitioner.";
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function writeVisual()
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"Visual
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This is the group term for the simple signals that provide an immediate understanding of a situation or condition. Worker managed and self regulating examples include: Colour coded dies, tools and fixtures. Lines on the floor to mark out stores, walkways, work areas. Kanban cards and boxes. Andon lights that go on whenever a stoppage or problem occurs and the engineer, supervisor can go right to the problem. ";
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