How to implement 'Unbreakable Set in Order' ?
+ 2 Ideas and 1 Image to kindle your thoughts
1 Article for the Week:
Tired of your team members not following the ‘Set in Order’? How can we strengthen the process? Here are some tips for Unbreakable Set in Order.
Suspend the Tools from above: Instead of assigning a place to put the tools back in the Tool Rack, suspend the tools from the top with a spring mechanism to pull it back once used. You can see it in many assembly lines
Fix it in the workplace: Instead of assigning a separate place for the tools, incorporated the tool in the process and make it a PokaYoke (Mistake Proof). e.g if you use a gauge to check the dimension of a part in a conveyor, fix the gauge in the conveyor itself. Now the products will pass through the gauge are OK parts, thereby eliminating the need for a separate storage + mistake proofing
Tool Elimination: Think about eliminating the use of the tool itself. We can think of 3 ways to do it.
Tool Unification / Combination - Can we combine the function of 2 or 3 tools into a single tool. e.g. instead of different wrenches, can we have a Multi-Hole spanner or adjustable wrench
Tool Substitution: Check the process and see if we can substitute the tool - by changing the materials used. e.g. if nuts and bolts are used in a process where a wrench is used, check If that can be changed to a butterfly nut, which may not require a wrench.
Method substitution: Check if the process can be modified (tool can be eliminated). e.g. Instead of nuts and bolts, can we use a One-Touch Clamp?
Can you try these ideas? Please share your thoughts.
2 Quick and Easy Ideas for Improvement:
Apply 1S and 2S in a Single Workstation: Remove unwanted items which are not needed for the current production from the workplace. Arrange the required items in a specific location. Mark a location / Label them for sustenance. Do this in the next 15 minutes and ask your team members to send a picture.
Identify one of the seven wastes: Go to Gemba (place of action) and observe any 1 process - at least for 10 cycles. identify the Value Added and Non-Value Added activities. How many wastes you can identify? What immediate action you can take?
Share with us in case you need any guidance.
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1 Quiz for the week:
Which one of these 20 points do you like? ______________
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