standard work instruction for toast kaizen (1) (1)

STANDARD WORK INSTRUCTION

FOR TOAST KAIZEN

KRISHNAN ESWARNITHIN BALAJIAZHAR NAWAZHARISH BALAKRISHNANARUN KUMAR GANESHASHWIN JUSTUS

INTRODUCTION

Problem:Production of incorrect quantity and type of bread at low quality due to the unavailability ofa standard work instruction sheet.

Objective:To study and analyze the existing facility and procedure, and provide a standard work instruction sheet.

LEAN MANUFACTURING

METHOD PURPOSE

Reducing Takt time by eliminating wastesTakt time is the time required to meet customer demand. By eliminating the seven wastes we can decrease Takt time.

Follow 5S principlesTo target and eliminate the bottle neck issue first and filter down to the smaller problems

Continuous improvement process All procedures must be questioned and improved periodically (6 sigma)

JIT (Just in time) Manufacturing JIT could be used to reduce or eliminate inventory

KAIZEN “Good-Change or Continuous Change”

- It is a tool used in lean manufacturing

- All members of the team are involved

- The objective is to improve the current process

- It aims at eliminating inspection by assuring quality at each stage

- Improving productivity by reducing waste

Operator Toaster Refrigerator

Bread Butter Knife Plate

Butter Microwave oven

MAKING A TOAST – EXISTING METHOD

Purpose: To make buttered toast for a customer

Resources used:

refrigeratorplate storage

area

work area

Toaster

knife storage

area

Bread Butter

26

1

3 5

4

Movement Legend

1 - To get bread2 - To get the plate3 - To replace bread4 - To get knife5 - To get butter6 - To deliver the toast to customer

EXISTING LAYOUT

GANTT CHART – EXISTING LAYOUT

PROCESS FLOW CHARTActivities Time(s) Symbols Distance Suggestions

Operation Delay Inspection Transportation Storage Decision (steps)

Movement towards the bread 4 4

Pick up the bread 2

Walk back to toaster 4 4

Movement towards the plate cabinet 3 3

Pick up the plate 4

Walk back to toaster 3 3 Layout could be changed

Place bread in plate 8

Place bread back 5 3

Walk back to toaster 3 3

Place bread in toaster 8

Set the toaster 2

Movement towards knife 3 1

Pick up knife 2

Movement back with knife 2 1

Idle time 17

Movement to take butter 3 3

Search for butter and pick up butter 16

Movement back to toaster 3 3

Idle time waiting for toast 89

Taking bread and placing it in plate 4

Move the plate 5

Cut the butter and apply to bread 49

Cut the bread 4

Movement towards customer 4 6

Return to toaster 4 6251 39

Ask customer's requirements

Place butter outside or microwave

Adjust the toaster settings

Use the time for value added chores

Pick required bread slices only

DEFECTS OBSERVED

STEP PROCESS DESCRIPTION TYPES OF WASTE REMEDIAL MEASURES

1 Move towards the bread Transportation

Place bread bag close by to eliminate motion

Place toaster to right of the sink

2 Pick up the bread

3 Walk back to toaster Transportation

4Move towards the plate cabinet Transportation

5 Pick up the plate

6 Walk back to toaster Transportation

7 Place bread in plate

8 Place bread back Over processing Can be done during toast time

9 Walk back to toaster Transportation Move the toaster

10 Place bread in toaster Overproduction Ask customers requirement & start production process

11 Set the toaster Over processing For perfect toast set the knob to 5

12 Move towards knife Transportation

The knife is not necessary 13 Pick up knife

14 Move back with knife Transportation

STEP PROCESS DESCRIPTION TYPE OF WASTE REMEDIAL MEASURES

15 Idle time Waiting

16 Move to take butter TransportationPlace butter at a visible place in refrigerator

17 Search for butter and pick up butter Over processing

18 Move back to toaster Transportation

19 Idle time waiting for toast Waiting

Clean dishes during this time.

Butter can be softened for 30 seconds

20 Taking bread and placing it in plate

21 Move the plate Over processing Butter spread can be reduced

The bread need not be cut

22 Cut the butter and apply to bread Overproduction

23 Cut the bread Over processing

24 Move towards customer

NEW LAYOUT

Refrigerator

Toaster

knife storage area

BreadButter

Microwave

Movement Area

• Standard work instruction gives specific and relevant information to the operator

• The SWI must be structured to eliminate the seven wastes

• It must be easy to understand and follow

• All safety precautions must be mentioned in the SWI

SWI – STANDARD WORK INSTRUCTION

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty

Incorrect Method Correct Method

Result Result

Standard Work Instruction

Work Element Sheet

Equipment/ Tools used

Name Purpose Name Qty

Ask customer for type of braedAsk - Bread Type- Quantity

Receive clear orders to avoid scrap

WORK STEP KEY POINT / SAFETY HIGHLIGHT REMARKS

1.1

Raw Material

Instruction Title Preparing a Slice of toast 10/29/2014 1Element Name Customer choice 1 0:03

Symbols

Q

Qty and type of bread unknown

Scrap

Bread qty and type known

-Bread quality -Over production ('x' amount saved)

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty

Incorrect Method Correct Method

Result Result


Work Element SheetInstruction Title Preparing a Slice of toast 10/29/2014 2Element Name Select Bread 2 0:08

Symbols WORK STEP KEY POINT / SAFETY HIGHLIGHT REMARKS

2.1 Take bread from storage - Pick right type of bread- Pick exact quantity To avoid scrap

Equipment/ Tools used Raw Material

Name Purpose Name QtyBread 1 - customer requirement

Q

- Pick more than requred- Pick wrong type of bread

WASTE!!!

- Pick exact amt- Pick right type of bread

-Bread quality -Over production ('x' amount saved)

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty1

Incorrect Method

Result


Work Element Sheet

Toaster Macine used to toast the bread Bread 1



WORK STEP KEY POINT / SAFETY HIGHLIGHT REASON WHY

Raw Material

Instruction Title Preparing a Slice of toast 10/30/2014 3Element Name Place bread into toaster 3 00:00:02

Symbols

Ensures bread is evenly heatedCheck proper seating of breadQInsert bread vertically into

toaster3.1Q

Correct Method

Result

-Toast quality -Bread is evenlytoasted

-Toast quality -Bread is unevenlytoasted

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty1

VisualsSteps to be followed:

Benefits:


Work Element Sheet

Toaster Machine used to toast the bread


- The toast might not be done on time- The toaster might not be on at all

- Check if toaster setting is at 5- Ensure click sound while turning on

QSwitch on the Toaster4.1


Raw Material

Instruction Title Preparing a Slice of toast 10/29/2014 4Element Name Switch 'ON' the toaster 4 00:00:01

Symbols WORK STEP KEY POINT / SAFETY HIGHLIGHT REASON WHY

Q

1. Machine process and safety check point.(click sound)2. Set the toaster knob to 5

1. Time wasted in double checking the toast process start is reduced.

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty1

Visuals

Benefits:


Work Element Sheet

Toaster Machine used to toast the bread



Toast the bread Ensure that the knob is set to 5The temperature of the toast should be at 154⁰C to get a quality toast


5.1

Raw Material

Instruction Title Preparing a Slice of toast 10/29/2014 5Element Name Toast the bread 5 3:36

Symbols

Q

The toaster set to 5 ensures that the operating temperature is at 154 degree Farenheit.

Ensures good quality toast.

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty1

Visuals

Benefits:

If adequate is not filled proper cleaning would not happen. Excess

quantity will result in improper removal of soap liquid.

Ensure the lock on the dishwasher is fastened properly.Close the door and switch ON.

6.2 Load the required amount of dishwashing powder. A scoop of dish washing powder to be loaded in the soap filling container in the dishwasher.


Work Element Sheet

6.3

Remove the wastes and dirt produced by the process that settles in the surrounding area.Clean and wipe the surrounding surfaces.6.4

Clean surfaces in the surrounding creates a positive work

environment and is helpful in identifying leaks or other

malfunctions in the machine.

6.1Place the dirty dishes in the appropriate positions

in the dishwasher storage.Visually inspect and segregate different utensils according to type and size, eg., plates, sppons, forks, boiling pans etc. Place them in the appropriate positions in the dishwasher.

Machine doen not operate until the lock is properly fastened.

Instruction Title Preparing a Slice of toast 16-Oct-14 6

For the utensils to be washed properly. Stains will remain in the

dishes if not placed properly.

Element Name Idle time 6 2:12Symbols WORK STEP KEY POINT / SAFETY HIGHLIGHT REASON WHY

Name Purpose Name QtyDishwasher To clean the dirty dishes Dishwashing soap Until the soap container is filled

Raw MaterialEquipment/ Tools used

Q

6.16.1 6.2

6.36.4 6.4

Q

1. Proper arrangement of the dishes is essential.

1. Fill up the soap container with the dishwashing liquid/powder.

1. Lock on the dishwasher should be properly fastened

1. Utilization of idle time. 2. Maintain cleaniness around workplace.

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty

VisualsExisting Procedure: Steps to be followed:

Benefits:


Work Element Sheet

Butter Available quantity



Take butter from fridge Remove butter from fridge 150s after bread is placed in toaster

To give optimum time for the butter to melt


7.1

Raw Material

Instruction Title Preparing a Slice of toast 10/29/2014 7Element Name Removing butter from fridge 7 0:12

Symbols

Q

Have to sort out the refridgerator to locate the butter.

Time wasted in sorting out the storage area.

1. Keep the butter on a designated place in the refrigerator.

1.Reduce the time utilized for taking out the butter.

Q

Issue Date Page

Element #

Element Time

Step# Symbol

Quality

Safety

Productivity

Qty1

Incorrect MethodSteps to be followed:


Work Element Sheet

Microwave oven To heat the butter



Microwave the butter - Microwave butter for 30s- Wear oven mitts. To avoid injury


8.1

Raw Material

Instruction Title Preparing a Slice of toast 16-Oct-14 8Element Name Microwave the butter 8 0:30

Symbols

Q

Butter is allowed to heat at room

temperature.

CAN'T SPREAD BUTTER!!

-Microwave butter for 30s

- Use oven mitts

Butter can be evenly spread

Issue Date Page

Element #

Element Time

Step# Symbol

Quality 9.1

Safety 9.2

Productivity 9.3

Qty1

Incorrect Method


Work Element Sheet

Knife To apply butter



Remove the bread from the toaster

Scrape butter using knife- Scrape 30 gms of butter- Spread horizontally from left to right- Ensure even spread

- To get quality output

REASON WHY

Raw Material

Instruction Title Preparing a Slice of toast 16-Oct-14 9

Spread butter on the bread

Element Name Remove toast and apply butter 9 0:14Symbols WORK STEP KEY POINT / SAFETY HIGHLIGHT

Q

Q

Correct Method

UNEVEN SPREAD!!!

- Output quality

GANTT CHART – NEW LAYOUT

PROCESS FLOW CHART

Activities Time(s) Operation Delay Inspection Transportation Storage Decision Dist

Ask customer about choice of bread and quantity 3

Pick up a slice from the bread bag and place one in toaster 8

Set the knob to 5 and start the process 3

Movement towards the sink 2 2

Clean the dishes 105

Return back to toaster 2 2

Movement towards refrigerator 2 2

Pick up butter 10

Return back to toaster 2 2

Heat butter in microwave 30

Wait for toast 60

Remove toast 3

Take knife 2

Apply butter 9

Movement towards customer 3 6

244 14

Symbols

CONCLUSION

By following the SWI as suggested we were able to make the right toast in the right

quantity with uncompromising quality

We can see that there is a significant improvement in the distance travelled between

existing and proposed layout

This can be extended to any production facility, but will be successful only if KAIZEN

principles are followed from top of the organization to floor level employees.

ACKNOWLEDGEMENT

• Dr. Sharukh A Irani

REFERENCES

• http://

www.dailymail.co.uk/sciencetech/article-2017338/The-perfect-piece-toast-Scientists-

test-2-000-slices-216-seconds-optimum-time.html

• http://www.mmsonline.com/articles/lean-manufacturing-for-the-job-shop

• http://www.mmsonline.com/articles/lean-manufacturing-for-the-job-shop

http://www.dailymail.co.uk/sciencetech/article-2017338/The-perfect-piece-toast-Scientists-test-2-000-slices-216-seconds-optimum-time.html




http://www.mmsonline.com/articles/lean-manufacturing-for-the-job-shop




standard work instruction for toast kaizen (1) (1)

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