2011 | Seite 3
The
Factory
DieLearning
Lehrfabrik
The
Office
DasLearning
Lehrbro
Tell me and I will forget,
Show me and I will remember,
Let me do and I will understand
Lao Tse
2011 | Seite 4
2011 | Seite 5
Shopfloor overview
before
2011 | Seite 7
Shopfloor overview
after week 1
2011 | Seite 8
2011 | Seite 11
Level 5
Full responsibility by
Level 4
Improve reached
Level by further
Level 3
Savings by
Cooperation
Level 1
Create proper
starting position
by
Flexible Work
in Teams
Selforganization
0-Losses
Benchmarking
Makigami
Structured
Problemsolving
Awareness of 16 Losses
5S Campaign
Targets and Roadmap
Zero Losses
Analysis of Tasks
Concept for Mobility
Room- and l&C-Concept
Visual Management
Team Boards
Structured Targets
Optimized
Teamwork
Processimprovement
Level 2
Optimization of
Best in class
100% Flexibility
0-Space
0-Throughput Time
0-Paper
0-Defects
2011 | Seite 12
week 1
3 days training
week 1
Implementation at
participants company
Project: 5S-implementation
Project: Implementation of a Standard
week 2
3 days training
week 3
Implementation at
participants company
3 days training
week 4
2011 | Seite 14
2011 | Seite 16
Process:
Individual or department /
action
Department 1
Which process ?
Step 1
1
1
Step 2
Department 2
Step 4
Department 3
Action time
Value adding
Losses
forms
forms
forms
data
medium
data
medium
data
medium
07:00 am
Day 2 07:00 am
07:10 am
07:30 am
1480 min
30 min
10 min
20 min
10 min
70 min
5 min
0 min
0 min
2 min
7 min
25 min
10 min
20 min
8 min
63 min
Data medium
Date
Step 3
Department 4
Data and
information medium
total time:
total action:
total value
adding:
0,54 %
2011 | Seite 17
red = problems
green = suggestion for improvement (as an idea repository)
2011 | Seite 18
sales
places orders
order processing
creates internal
confirmation and
production order
scheduling
customer
provides
components
billing
shipping
production
2011 | Seite 19
customer
billing
creates shipping
documents and packs
clipboard
shipping
order processing
assembles
clipboard
scheduling
creats bill
sales
production
2011 | Seite 20
I order my clipboard at
the training company
Clipboard Ltd.
2011 | Seite 21
2011 | Seite 22
2011 | Seite 23
I create the
production order
2011 | Seite 24
I schedule all
components for
production
2011 | Seite 25
I assemble the
clipboard
2011 | Seite 26
2011 | Seite 27
2011 | Seite 28
Impressions
2011 | Seite 29
Impressions
2011 | Seite 30
Impressions
2011 | Seite 31
Production
Production
Office 1
Employee 2
Training room
Billing
Logistic
Office 2
Post Office
Customer
Scheduling
Shipping
Employee 1
Sales
2011 | Seite 34
Shipping
Information
Material
Production
Billing
Scheduling
Employee 1+2
Sales
Training room
Logistic
Post Office
Office 2
Customer
2011 | Seite 35
2011 | Seite 36