Ohno Circle-Observe & Identify Waste
Ohno Circle tool was developed by Taiichi Ohno, the father of Toyota Production system. The main purpose of this technique is to observe & identify waste around us.
Kizuki is a Japanese word & means “Ability to Notice”
- Choose a location in your work environment.
- Silently stand and observe for 30 minutes.
- Observe the process flow, floor layout, materials, persons, etc.
- Write all observation that result in any kind of waste, viz: space, energy, time, motion, waiting, transportation, safety, abnormalities, concerns that you feel can be done in better & efficient way.
- Take pictures, if possible for future record.
- Develop ability to notice.
- Hidden wastes will become visible.
- Dedicated actions on observations will improve efficiency.
- Develop Team to observe the things.
Introduction to 5S – Super Organiser
The 5 steps of 5S – Super Organiser are as explained below:
This process identifies the items that are required to perform work in the work areas. Clear (sort out) all other items from the work area. It has following benefits:
- Efficient use of work space
- Improved safety
- Improved productivity
- Improved utilization of materials, supplies, and resource
- More visible work flow
- Improved employee satisfaction
- Improved quality
Set In Order:
Aplace for everything & every person at its place. This supports in ease for retrieval. It has following benefits:
- Elimination of 7 wastes and ease effort needed to search for or retrieve tools and supplies.
- Easy identification of any missing tools
- Improved safety through an organized workplace
- Increased productivity
Proactive/preventive housekeeping to keep work areas, work surfaces, and equipment clean and free from dirt, debris, oil, etc. Benefits:
- Cleaner and more satisfying place to work
- Improved Quality standards
- Maintenance issues exposed faster (planned downtime vs. unplanned downtime)
- Improved safety (fewer accidents)
- Improved work culture
Do things in a consistent and standard way. Formulate standardize procedures for activities, instruction, schedules, checklist for helping keep the workplace clean and organized. Standardize work area layouts and storage techniques wherever possible. Visual Management implementation for ease of maintaining standardisation.
Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.
Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)
This is a beautiful case study resembling positive approach of the team towards finding solution.
A stack analyser was having very high frequency of maintenance. Being mounted in stack of incineration plant, the probe was exposed to dust & acidic gases, which were the main cause of probe failure. Main Issues with the Analyser is:
- High Frequency of Cell and heater failure.
- Frequent chocking of cell assembly.
- High time required for cleaning and cell replacement.
- High cost of maintenance
The team took up the challenge to come out of the issue. The study done was a good example of usage of various reliability tools like RCA, Fishbone diagram, Brainstorming, etc. ,there is another angle to it, ie. Lean Management. The main objective of the study was to reduce the quantity of jobs performed on the analyser.
The team has recently gone through “7 Wastes-Mr. TIMWOOD “. They decided to identify the wastes in the activities on the analyser. All the activities were identified & written.
Each activity was studied and type wastes were identified.
Analysis of the identified waste is as under:
- Transportation of probe to the repair location: Can the probe be repaired at the installed location?
- Motion of the workmen for steaming, hammering & temporarily electrical connections: Why Steaming, Hammering is required? Why temporarily connections are required?
- Defect during leak checking: What is the procedure for ensuring correct assembly?
- Inventory: How to reduce inventory required supporting the frequent maintenance?
- Waiting: Why can’t the warm up done at location?
- Over Processing: Why calibration & response check is required two times?
The next step was to find answer to these questions. The maximum time was consumed by removal of Cell & seal assembly. RCA tool, Why Why analysis was used to drill down to accumulation of the acidic dust at the cell as the root cause. A ceramic diffuser was prepared with OEM, to put in place of mesh, which is more capable of filtering dust. This small change after value engineering has resulted in substantial improvement in terms of time, cost, inventory, maintenance frequency, reliability & availability of the instrument.
Cost of Modification: Rs. 25000
- Total time of job was reduced from 8.8 hours to 4.3 hours.
- No. of jobs reduced from 10/year to 4/year.
- Material cost reduced from Rs. 1.8 Lakh to Zero.
Experience of industries has been concentrated in different quality, Reliability & Lean tools. Correct knowledge & implementation of these tools is necessary for best results.
Case Study- Frequent maintenance in Stack Analyser (Lean Tools)