Manufacturing Engineer

Were you a "BMOC"?

Here are some websites for 5S and TPM. Good luck.

http://www.graphicproducts.com/tutorials/five-s/index.php

http://www.plant-maintenance.com/articles/tpm_intro.shtml

thanks dude..........

Hi Dmiriy10,

What process we talk about? Anyway, I suggest to read two books to apply to processes: K. Suzaky's "The new manufacturing challenge" and S. Shingo's "A revolution in manufacturing".

When we get the products or items to make, you can get more and precise information, Gil.

Theres a process to every process :) . For the SMED you need to find something in common with the other products so you can standardize as much as possible the production line. REMEMBER THAT THE OBJECTIVE IS TO REDUCE SETUP AND LINE CHANGE TIME AS MUCH AS POSSIBLE. You will need to make a flowchart of your process including the times of each operation. Break the process times as much as you need (maybe you will not need micromovements but enough so you can interchange times from other products). Study all of the processes and their differences, layouts, people needed, takt time etc. Then you will start making the new integrated line in paper, simulate it and see how it works, what do you need etc. Once everything is in paper and simulated then start acting, make fixtures and tools that will help to make the line change faster. Use carts, wheels, stands etc. Have the materials ready on the line in special boxes. Train the operators to have it all on order and whos gonna do what, where the material bins are going. Time them and film them the before and after!! THIS IS CRITICAL! YOU CAN SHOW THIS TO UPPER MANAGEMENT AND KEEP YOUR JOB FOR A WHILE!! ;) ALSO, CALCULATE SAVINGS, HOW MANY MAN HOURS DID WE SAVE (BEFORE /AFTER? ASK FOR THE COST OF AN OPERATOR HOUR AND FIND OUT HOW MANY TIMES YOU NEED TO CHANGE BETWEEN P/Ns.

5s is part of a industry culture. You need to enforce it daily. You can apply it to the materials and tools on the prod. line. Its pretty simple, I don't think you will have a problem here. If something looks crouded of crap then clean it up and teach the operators to do this daily before going out. There can be many stages, if its a real mess then try to make 1 or 2 steps a day and give follow up. Make some control format so you can sign what hour did they do the clean up etc.

TPM. You need another format including the date, technician etc with all the machines you are responsible for. If you can make the mantenance at lunch time or 2nd shift, maybe change the work hours and have the technicians stay half hour more. Also, always when you are making the mantenance put an indicator on the machine so if the technician for some reason leaves the operator in the morning knows that the machine is not working and should not be used.

Well.. those are all the pointers I have so far. My suggestion is to read just a little bit, it is really simple. Its just a matter of breaking up your tasks in smaller ones and make a program, get organized and youll do fine. If possible get a team and program all of the activities yo need to do to achieve the implementation.

Engage