All the employees are involved in taking Kaizen Shapath

Yogesh Vaghani, Director, Milton Plastics in an animated discussion with Frontline Employees

Director to Doorman - all are equally involved in doing Kaizen at GEMBA

Preventive Maintenance through Visual Management

Visual Management – Pigments stored in all the containers are visible and known

Transparent containers

Through color coding, it is easy to know which tools and components belong to which dept.

PEEP (Place For Everything and Everything in its Place) When the person has taken a tool, he will place a token at the place that will let others know where the tool is now and with whom

Token

Standard WIP

Output

Input

1. Frontline workers are cleaning their workstations to keep their workplace dust-free2. Standard WIP has been kept near every workstation3. All the components have been color coded according to their functionality and stored at the point of use (POU)

Color coding

This is an example of One Piece Flow AssemblyEach and every component needed is available at a hands distance of the worker

Plan vs. Actual production

display board

Light indicator to give signal

Packaging

Material at hands

distance

Learning Center - where all kinds of tools are kept to train the employees

Worn out/Waste tools are kept in

one line

SMED trolley

All the tools required (related to the machine) to perform the changeover are available in SMED trolley. Big stand is available in the left corner where all the tools are kept that will be needed during changeover, it helps to avoid Muda of Motion & Transportation

SMED trolley contains all the tools required to perform quick changeover. SMED trolley has been parked only in the right area

Responsibility has been assigned to

Shift Fitter

• Place for everything and every useful thing in its place (PEEP)• Kanban system• No stock out or over-stocking of material

Kanban Collection

tray

Once any material has been picked up for use, the Kanban card of the particular material will go into the Kanban collection tray. It will then be sent to purchase department at every 11 am & 4 pm daily for placing the replenishment orders

Whenever the operators need some material, they trigger the light that gives signal toMizusumashi (Water Spider) who replenishes the required material in the workstation

Mizusumashi (Water Spider)

Light signal

Point of Use Storage (POUS) with Kanban

Responsibility assigned

Kanban Card

Kanban Board

Visual Management

Count Free

No Oil Drops on the Floor

Name of the Oil stored

Same color marking is

done on M/C

Place For Everything and Every Useful thing in its Place (PEEP) in Table Drawer

Kaizen For kids (KFK)

Yogesh Vaghani discussing the importance of Kaizen with School Faculty