My manager just approved a new project where I’ll practice Toyota Kata. The challenge for one department is a 10% reduction in Yield Loss for the year. The first Target Condition is the ability to track daily Department Yield loss per PO. Current Condition is overall plant yield loss once PO is closed out, which can take days. submitted by /u/Go_Further_ [visit reddit] [comments ..read more

Hello people, I was wondering if you guys could help me on this. What are the best ways to organize these coils so we can identify them better? We don’t have a lot of space in the warehouse so it can be tricky. We have three different lengths: 1500mm, 1250mm and 1000mm. For each, we have different thicknesses: 1.5mm, 2mm, 2.5mm and 3mm. We keep stock of 1 unit of each length and thickness. What would be your recommendations? The image is merely representative. submitted by /u/Jh4nTy [visit reddit] [comments ..read more

Ho, does anyone have any experience of taking a multi-step process, and finding a way of visualising it without having so many separate stauses and dates for each one, for example, I have something like: Brief Received Quote Provided PO Raised Samples Provided Samples Approved In Production In Transit Delivered As my steps that need to be completed, each one of these jobs is of medium value, and these steps are usually fairly quick and easy to do, we definately need to track what stage each project is in, but at the same time it feels like a lot of information when one person probably has h ..read more

I have taken up a job as a process engineer for a blown film company a little over a month ago. I have experience 14 years in blown film from my previous company, but I learned from filling in production operator and process tech roles (I am not a degreed engineer, fyi.) Continuous improvement was an integrated concept in my previous organization, but not so much in the new one. I want to help champion and inject CI into the workplace to help improve operations, improve the employee and work culture, etc. I do have a decent grasp on CI/Lean/6sigma concepts and techniques, but I want to build ..read more

I recently started working at a smaller manufacturing location. We have plenty of time to complete the required orders. What I am struggling with is how to get past the operators asking “so you want us to hurry up so we can wait?”. I am hoping to get our machines being monitored for OEE, but it is a hard sell right now. Do any of you have experience, books, or websites that might help? I came from a large manufacturer that had a good lean system in place and I would like to replicate some of the tools here. Thanks in advance. submitted by /u/pakalika [visit reddit] [comments ..read more

Hey everyone, I'm currently an industrial engineering student diving into my final project, which revolves around optimizing feeding flows in the assembly line of an automotive injection factory. Specifically, I'm focusing on the assembly of door panels, incorporating semi-finished components like armrests, after the injection process to achieve the final product. The project is centered on enhancing feeding flows in the assembly line and identifying wasteful practices to suggest improvements. It involves two assembly lines with distinct processes. We're looking closely at how components and ..read more

I'm trying to study about forklift usage. I mainly need to track distances traveled and idle time (I guess knowing when velocity equals 0 would work). If possible, tracking routes thorough GPS would be interesting as well. How could I do that using solely an android app? (prefferably a free one). Being able to import the data to an csv or any extension that could be converted to a spreadsheet would be important. submitted by /u/yarnyy [visit reddit] [comments ..read more

I'm trying to design some training modules for our teams, we're not a manufacturing company, we offer outsourcing services, so finding some relevant examples and case studies can be hard. I do like a lot of the hands on exercises to illustrate key principles by having a go, usually have the teams making things from lego or folding or drawing on bits of paper. We tend to do a lot of remote working so I wanted a virtual version. This is by starter idea, this is a production line where the three stations make the three products illustrated, there are three participant, but of course I could add ..read more

Throughout the years I’ve attended a few green belt courses but never belted due to job changes and not finishing my project. My boss has just approved me attending BB course. Any recommendations? Id rather not go through GB again. Looking for a reputable online program that would help prep me for ASQ BB certification. I read from a post here that’s the one to get. I assume that’s still true, let me know if there are other reputable certifying organizations. Thank you submitted by /u/Go_Further_ [visit reddit] [comments ..read more

Afternoon All, I have a chance to pitch to my board that we should embrace Lean methodology in a month or so's time. They're not manufacturiting / engineering people, more relationship builders, so I need a way to communicate the benefits in a short but powerful way. Quotations that back up the key benefits are the way I'm thining of going, they need to be from a universally known figure, rather than someone known within the Lean world. I came up with a few, very grateful if anyone has any other suggestions: “Time waste differs from material waste in that there can be no salvage. The easiest ..read more