Kaizen Blitz Projects line packing Aug 2011

1. Kaizen Blitz:
Projects Line Packing
Alan Magner
Thursday 25th August, 2011
Contact:
alanmagner@variancereduction.com

2. • 1-day event to improve safety & housekeeping in the Projects Line packing area
Agenda
 Improve the housekeeping at the Projects so the walkways will always be kept clear
Target
 Walkways are kept clear
 All pallets have a designated place, and are kept in their place
Results
 Maria Santa, Borka Todorovic, Disco, Zhi Hui Zhu
Involved

3. Problem Statement
Walkway for people & forklifts was restricted by trolleys and by pallets of inventory
Action
1 day kaizen blitz to improve safety – using 5S principles to improve housekeeping and improved workflow, and
employee engagement to sustain the changes
Before After

4. Before: no access to racks
Problem Statement
 pallets of cardboard for packing are blocking racks of inventory
 Future plan to remove racks – new location needed for cardboard
Action
 Re-located safety bollards – cardboard now closer to point-of-use – cardboard pallets have a dedicated place
After: Storage for cardboard inventory

5. After: Dedicated place for finished goods
Problem Statement
 Pallets of finished produced faster than can be collected by warehouse
 Not enough space for pallets of finished goods
Action
 Dedicated place for finished goods (6 pallets) – location supports future process changes
 Dedicated place for empty pallets (8 pallets)
After: Dedicated place for empty pallets

6. Before: Space not utilised well
Problem Statement
 Limited space at end of projects line
 Large numbers of pallets (cardboard, finished goods, empty pallets) – all need a location
Action
 Simple, quick, low-cost change
 No compromise in safety standards by moving bollards
 Inventory closer to point-of-use
After: Dedicated place for finished goods

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