Aluminum Die Casting 3.1.2 Visual Workplace (6S).

Aluminum Die Casting

3.1.2 Visual Workplace (6S)

Accelerating Supply Chain Performance

Company Profile ESTABLISHED IN 1950 3RD GENERATION FAMILY BUSINESS DIE CAST MANUFACTURER WITH AN

EMPHASIS ON ADDED VALUE MIRA LOMA, CA 32 EMPLOYEES WE HAVE BEEN WORKING ON THE SEA

ROADMAP FOR APPROXIMATELY 11 MONTHS PRIMARILY SUPPLY MILITARY AND

AEROSPACE

2


Our Products

SURVIVAL BEACON

M.I.L.E.S TRAINING


6S Visual Workplace 3.1.2 We began with an all hands training power point presentation

by the leadership team. Then we broke down into departments for emphasis on each area’s individual needs.

The 6S status is displayed with the current audit in each department, process flow is defined with floor markings, production status is shown with each bin tag, employee training status is noted on dashboard matrix, and continuous improvement is clearly displayed and visible on the dashboard and photos.

Improvements reviewed and recognized through monthly audits and feedback, as well as daily encouragement by the

leadership team.


Process showspositive trends

Process measured,analyzed, and improved

Process standardized

Process documented

Process identifiedand process ownerassigned

5

4

3

2

1

The Process Maturity Model


Process Flowchart

Training Sort Set in Order Shine Standardize Sustain

Safety AuditScorecard

Report

Reward

Score less than 90

High Score


TRAINING Training power point was developed by

leadership team Program is presented in an all hands meeting

by the leadership team in English and Spanish to be certain it was well understood

Comments and discussion is encouraged and productive

Divide into small group sessions by department

Retrain yearly


SORT Eliminate everything that is not

needed in each work area Red Tag event for each department Make certain that everything that is

needed is close at hand and organized so no time is wasted looking for things


SET IN PLACE Developed shadow boards & tool

carts to standardize equipment placement

Labeled containers & shelves Defined areas for part movement in

and out of departments Defined equipment locations


SORTING AREA


LABELED STORAGE


CNC CART


DIE CAST CART


VISUAL MANAGEMENT LINES & SIGNS

FLOOR MARKING COLOR CODEINCOMING WORK

OUTGOING WORK

FIRE EXTINGUISHER

WALKWAYS

EQUIPMENT


LINES & SIGNS STANDARDIZE LAYOUT


STANDARD LOCATIONS


VISUAL INDICATORS


CNC SET UP AREA


SHINE Cleaning equipment on shadow board

for each department Encourage keeping work areas clean

while working to increase productivity The job is not complete until your area

has been cleaned and things are put away


CLEANING SHADOW BOARD


STANDARDIZE Monthly audit of each department to

review that first 3 S’s are maintained Photos of what each area is to look

like are posted to document standard Visual indicators in place to keep

parts moving through the shop


AUDIT FEEDBACK & STANDARD


OFFICE SUPPLY CLOSET


MAINTENANCE DEPARTMENT


CNC SETUP AREA


ITEMS TUCKED BEHIND MACHINES


SUSTAIN Monthly review of department scores Rewards for scores above 90 Yearly retraining


6S Score CardOutgoing

Incoming

Equipment

Aisle Way

FLO

OR

ST

RIP

ES

DE

FIN

ED

Fire Extinguisher


SAFETY Monthly all hands safety meeting Quarterly safety walkthroughs with outside

consultants Post quarterly safety meeting notes on

dashboard


AUDIT

6S Area: (Name the work area)Date: Scored by: Item Score NoteSort Distinguish between what is needed & not needed

(Organize) Unneeded materials or parts?

Unneeded machines or other equipment?

Unneeded items marked for removal?

Procedure in place for removing unneeeded items?Straighten A place for everything and everything in its place

(Set In Walkways clearly identified

Place) Work areas, locations clearly identified

Item indicators (shadow board, labeled shelves)

Tools arranged to facilitate efficient useShine Cleaning and looking for ways to keep it clean

(Cleanliness) Work area, equipment clean & free of debris

Cleaning materials available & accessible

Aisle markings, location indicators clean, unbroken

Cleanliness is a habitStandardize Maintain & monitor for adherance

(Adherance) Improvements implemented and documented

SOP for reviewing first 3 S's in use

Visual Indicators in place and in use

Standard methods documented and in useSustain Following procedures to sustain improvement

(Self Discipline) Procedures being followed

Ongoing Audit and Feedback system in place

Action Plans are created based on audit results

Good habits are re-enforcedSafety Maintaining a safe work place

(Zero Incidents) Appropriate controls in place to use equipment safely

Weight limits being used

45° rule being followed

Strike Zone storage to reduce back strainScoring 1 = Random, unidentified conditions 4 = Reliable methods and standards in use

2 = Indentification, plan in process 5 = Preventative actions are common

3 = Visual indicators in place 120 possible points 90 points triggers retraining

6S Audit Form

Three person audit team walks through each department monthly and scores each “S”

Communication is made at that time & via printed report of the audit

Action items are created and followed up for continuous improvement

Photos are updated for the “New Normal”

Feedback for improvement of the process is solicited


THANK YOU

Aluminum Die Casting 3.1.2 Visual Workplace (6S).

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