FINAL PROJECT

Apply ‘Lean Principle’ on ‘Family Cord’

Product Assembly Line

at

NEW HORIZONS COMPANY

MSE 507

Lean Manufacturing Systems

Project Guide:

Professor S. Jimmy Gandhi

Team 04

Renan Gama

Viral kumar Jayswal

Perparim Rushiti

Pooja Chintakunta

Ranmini Menikdiwela

Content

• Introduction

• Current process

• Gemba Walk

• Value Stream Map

• Root Cause Analysis

• Waste identification

• Project Goal

• Process Improvements

- SOP and Operation Tool Box

- Poke Yoke

- 5S implementation

About New Horizons

About New Horizons

New Horizons is a local organization located in the San Fernando Valley, which helps

people with special needs and disabilities to develop significant skills that can be useful in

different work environments.

New Horizons has been working in partnerships with several departments and colleges at

CSUN.

This collaborative project is a partnership between the Manufacturing Systems

Engineering Department and New Horizons, and our group was chosen to work with the

Family Cord packing, in order to develop recommendations than can help New Horizons

to have a better-flowing process and therefore reduce costs.

About Family Cord Packing

The Family Cord Kit consists of two finished kits, Stem Cell Kit and Cord Blood Kit

Regarding the materials used for the assembly of the Family Cord Kits, Family Cord

stores some items at new horizons such as the boxes, foam packing inserts, and

other few items. Usually, Family Cord company send assembly orders to New

Horizons Production Department and the kitted raw materials to New Horizons

Warehouse.

Gemba Walk

•Gemba walk throughout the operation process

•Baseline for a Value Stream Map Understanding the time lines of the sub

operations.

•Examine the actual process involves

•Interaction with the people associated with the process rather than only

reviewing documentation.

Value Stream Map

Root Cause Analysis

Waste Identification

The waste (MUDA & MURI) identified in the project of Family assembly ‘Waiting’ of supervisor & operator

- Instruction sheet folding & Box folding process- Operators are waiting to get assistance from supervisor, but same time supervisor

is busy to assist other operator.- Do not have proper tool & ‘SOP’

‘Unnecessary motion / transportation’ of supervisor- Supervisor moving here & there in assembly line to train the operator,

inspection of the process/product ‘Over processing’

- Sheet folding process ‘Overburden’ of Supervisor

- Unnecessary workload at one time, Supervisor performs multitasks; training, inspection & box folding operation

Project goals

Instruction sheet folding process(takes time 26.5 sec each)

Box folding process (takes time 110 sec each)

Make production line neat & clean, spacious & well Organized

by removing unneeded stuff.

Lean tools

- Value stream map

- Fishbone diagram

- Error Proofing (Poke Yoke)

- 5S

Standard Operation Procedures

SOP

Standard Operation Procedures for the Family Cord Packing operations –

- There are 10 basic operation steps in the Family Cord packing process (Stem Cell Kit packing)- Standardize Family Cord - Stem Cell Kit packing process- This leads to reduce waiting time for supervisors - Unnecessary workload for supervisors will be reduced

Operation tool box

Operation tool box for trainees –

Operation Insert pre - fold worksheet into the bag

Step 1 Wear Gloves

Step 2Insert pre fold worksheet

into the bag

Operation tool box

1. Operation tool box for trainees –

Operation Pre - fold work sheet in to half

Step 1Fold work sheet by

half

Step 2 Creasing

Operation tool box

2. Operation tool box for blind workers –

Insert pre fold worksheet into the bag

Step 1

Step 2

Operation tool box

2. Operation tool box for blind workers –

Pre Fold work sheet in to half

Step 1

Step 2

Error Proofing (Poke Yoke)

De-skill the paper folding operation - Folding work sheets in half is one of the main operations carried out in the Family Cord packing process. (Picture)- The main concern it is required person with enough dexterity to carry out the task of folding properly and effectively. - Operation steps •Fold the paper by half•Creasing - We observed the trainees are performing the task by folding and creasing the paper by hand.- However they find it difficult to perform at required level of quality.- Therefore it takes more time to perform.

Poke Yoke

1. Developed worksheet folding devise 1

De-skill the paper folding operation

Design is based on ease of use that requires little coordination and handling skills.

It allows the trainee to easily fold the worksheet with the use of few simple steps.

1. Insert paper in the devise (follow the vertical gauge)

2. Fold the paper in half (follow the horizontal gauge)

Poke Yoke

2. Developed worksheet folding devise 2

De-skill the paper folding operation

1. Insert paper in to the devise (follow the horizontal gauge)

2. Make the crease by folding down the paper

Half page length

Poke Yoke

3. Creasing device for paper folding

De-skill the paper folding operation

1. Insert paper in to the devise (follow the horizontal gauge)

2. Make the crease by folding down the paper and fold the paper

Box folding method

Box folding Method

Box folding method

Box folding method

Box folding method

5S implementation

- Some trainees keep their bags near

them while working, under their seats

or hung in their chairs. (Dedicated

space to keep their bags)

- Table used to assembly the kit and

close the box was full of unneeded

items taking a lot of space (Such as

ornaments, water bottles, etc).

- Remove unnecessary items and

keep just the essential ones for

the operation.

1. Sort - Remove all items not needed for current production/operation and

maintain only the essential items.

5S implementation

2. Set - Arrange required items in a way that is easy to use.

- Unnecessary motion was observed in the operation of assembling the kits.

- With the Sort step concluded, items finished by trainees can be arranged

in the same table in which the staff employee finishes the kits and close

the box.

3. Shine - Keep clean the workplace every day by eliminating dirt and dust.

- Although there might be a schedule for cleaning, we recommend to establish a

new schedule for cleaning everyday, in every shift change, with some

modifications in order to sustain the cleanliness and the new layout suggested

in the previous steps.

5S implementation

4. Standardize - All the best practices and new procedures recommended in the

previous 3 steps must be standardized.

- Develop standard procedures for the operation of Family Cord Kit

assembling. (To be performed every time a Family Cord Kit order is placed

by customer).

- Develop standard procedures for the placement of trainees over the

production line, accordingly with the sequence of processes and trainees’

skills required. (To be performed every time a Family Cord Kit order is

placed by customer).

5S implementation

5. Sustain - Making a habit of properly maintain the correct procedures.

- Checklists: the use of this tool can be very useful in many operations and in

many levels inside the company to ensure that all the items in the list are

being done.

- Inspections: someone has to be responsible for inspecting if the correct

procedures are being followed.

- Auditing.

- Culture change: all of the employees have to acknowledge the new

procedures and the importance of them for everybody inside the company.

Questions?

Thank you…