Efficiency can be defined as amount output derived from inputs. it is directly linked to resource optimization. Today business environment is very competitive & cost of product plays vital role in driving sales. Let’s discuss top Seven Must-to-do Things for Efficiency Improvement. The cost of production is depended on raw material, labour, overheads etc. The way any company uses these resources derive the final cost of product. There are many tools available for using these resources more efficiently. Seven mostly used & simple tools are summarized as below:

  1. Visual Management: The items placed at workplace should talk to us. few examples are:
    1. The instruction board on machine should tell how to operate, what alarms to look for etc.
    2. The color coding should tell which cylinder has which gas.
    3. The production board should tell, target for the day, week or month & status and so on.
    4. Posters with information on risk, procedures etc.
    5. Labels like Hold, Out of Service
  2. 5S: This is the basic tool which is based on principal that, the work place should be clean, sorted, standardized, Systematic & sustainable.  The terms are common to many industries viz. Sort, Set-in-order, Shine, Standardize & Sustain. Utlities like shadow boards, Peg boards are very helpful for organizing the work place. Red tag system is the starting of 5S in a company. Small 5S kit are available for start the 5S journey & feel the benefits of it’s fruits. 2-inch Metal Peg Board Shelving Hooks | 50-Piece Pack| www.breval.co.in
  3. Kaizen: Suggestion are nobody’s monopoly and can come from any level in organisation. Every Suggestion has to be treated with due respect. Culture shall be created to invite and motivate the whole team to contribute with ideas. These ideas shall be evaluated & awarded to get the system going. Small improvement in system result in continuous improvement. Simple Suggestion box & formats are only required to begin the kaizen system.Suggestion Idea Box kaizen implementation
  4. Safety Culture: Safety is not directly linked with production but any unwanted accident can result in loss of asset, life & reputation & has potential of completely shutting down the business.
  5. Skill Development: Skill is a diminishing inventory if not used & upgrdaed with time. Thus, two things are very important. One is to use right skill at right place at right time, otherwise this will got wasted. Other is to continuously upgarde the skill level to be in pace with changing requirement. Inhouse training should also be given to team for refreshing the concepts.
  6. Integration of Information Technology: IT has got in to every sphere of life, be it industry or society. A company shall use IT to leverage its power to make the systems more efficient. Data capture & analytics has become a big thing in today’s scenario. If a company is not on internet, it is lacking share of market to it’s competitors.
  7. Seven Basic Quality Tools: These Seven quality tools include cause and effect, Check sheet, control chart, Histogram, Pareto chart, Scatter Diagram & Stratification. These are most basic tools which should be applied to work environment to identify the root cause & design solution.

These are only few of the tools which are very important to bring up the efficiency of any company’s work environment.

#Top Seven Must-to-do Things for Efficiency Improvement

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Poster-Visualizing your thoughts

Posters are great way of visualization the power of learning.

People remember things more, if they visualize things. The posters located at strategic location helps in conveying message of the top management to the whole team. Posters are the messages to all. Things that are important for best poster building are;

  1. The poster should convey the message.
  2. The Poster should be in language of people.
  3. Posters should use pictures, graphs etc.
  4. Posters should be interactive, They should talk with people.
  5. Posters should be attractive.
  6. Posters should be specific.
  7. Poster material should be long lasting.
  8. Posters should be smart and has capability to link with people.
  9. Poster size, font size should be visible.
  10. Posters should be innovative.

10 important things for creating highly effective posters

Few examples of best posters used for visual management in 5S, root cause analysis, lean management etc. are shown as below:

Poster-Identifying MUDA

7 Wastes poster-Lean management

RT1

The Red Tag System-Sorting process in 5S

5S Planet Poster

5S poster- Lean Management

5S Pyramid Poster

5S poster- Lean Management

5S Structure

5S poster- Lean Management

Poster-Root Cause Analysis

Root Cause Analysis- 5 Whys

Poster 5S Methodology

The posters requires creativity & innovation. Many software are also available for making posters. very basic software & tolls that can be used for making poster are as below:

  1. Paint
  2. Microsoft publisher
  3. Power point
  4. Microsoft word

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Many online tools are also available, but these are the very basic tools, which will full fill majority of the requirement.Go ahead & create your own posters. Think freely & innovate something new and benefit the society.

Key words: Lean management,lean management tools, visual management, 7 waste,5S cycle, 5S lean, 5 s lean management, zara lean management, why lean management, using lean management, under 5s, 5s walks

Are You an Innovator!!!

Innovations is no body monopoly. Rightly said, innovation can come from anyone, may be a road side hawker, a 5 year old child, an illiterate farmer, an engineer, a sales person, a student, a scientist. Innovation, knows no boundaries & limitation of education, age, profession, etc.

innovators

Innovation needs a “problem to be solved” & “dedication for finding the solutions”. Majority of the times, innovation is only small changes made in any environment, that may have a very large impact.

We have many ideas flowing all around, idea can yield results, only if they are implemented in systematic way. India has vast opportunities for innovation in all spheres of lives. We also have potential to tackle all challenges in simpler ways.

We are looking for such innovators, who want to make a impact by simple changes in lives of people. We invite such people to work with us.

  • Are you good at innovation?
  • Have you designed something creative?
  • Is you creation, need of the future?
  • Do you want to commercialize your innovation for benefiting the society?
  • We have a attractive a option for you!!!

Attention innovators!!!

  • Innovators, who have ready working model of their project should send synopsis of your project on rds@breval.co.in
  • Selected candidates will be called for further discussions.

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5S Structure

 

Introduction to 5S – Super Organiser

The 5 steps of 5S – Super Organiser are as explained below:

Sort:

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

Shine:

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

Standardize:

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.

Sustain:

Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.

Workshop on 5S

We have designed special products for 5S like Red tag, Posters, Lean Storage etc. Please visit our Online shop.

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Time Management

Time management

Time is a precious & scarce resource. Every person has 24 hours in a day, 365 days in a year. How effectively & efficiently, a person manage to use the limited time resource, differentiate s successful person from others.

We have too many jobs floating in our head. we try to hit one, other starts giving worry. The right way is to prepare a To-Do list. This will help in easy management of multiple jobs. There is a structured yet, simple way for time management tool.

 

Steps:

Collection:

Write all the task at hand.

Pruning:

Whether, I should do it? Leave non essential & non value added tasks.

Organizing:

Break all the larger tasks into smaller activities.

Group together activities, which can performed together.

Prioritize:

Prioritize the activities with Johari window

Time matrix, Johari Window

Execute:

Finish task as per priority assigned.

Benefits by To-Do list:

Carry out all necessary tasks.

Tackle the most important jobs first, and don’t waste time on trivial tasks.

Don’t get stressed by a large number of unimportant jobs

All jobs are written, thus no job is lost.

More job can be done in same time.

Effective Management, helps in relieving stress level.

you would also like to have a beautiful poster designed on time management in your office.

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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.

Case Study- Frequent maintenance in Stack Analyser (Banish MUDA)

Analysis of the identified waste is as under:

  1. Transportation of probe to the repair location: Can the probe be repaired at the installed location?
  2. Motion of the workmen for steaming, hammering & temporarily electrical connections: Why Steaming, Hammering is required? Why temporarily connections are required?
  3. Defect during leak checking: What is the procedure for ensuring correct assembly?
  4. Inventory: How to reduce inventory required supporting the frequent maintenance?
  5. Waiting: Why can’t the warm up done at location?
  6. 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.

Continuous Improvement

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.

Continuous Improvement

Experience of industries has been concentrated in different quality, Reliability & Lean tools. Correct knowledge & implementation of these tools is necessary for best results.

Check other case studies on Vanilla Ice Cream and Flight 5390 failure.
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Case Study- Frequent maintenance in Stack Analyser (Lean Tools)