What is 5S Concept? Simply put, 5S is a method/Japanese concept for organizing a workplace, especially a shared workplace (like a shop floor or an office space). It’s sometimes referred to as a housekeeping methodology, however this characterization can be misleading because organizing a workplace goes beyond housekeeping (see discussion of “Seiton” below). The key targets of 5S concept are workplace morale and efficiency. The assertion of 5S is, by assigning everything a location, time is not wasted by looking for things. Additionally, it is quickly obvious when something is missing from its designated location. 5S advocates believe the benefits of this methodology come from deciding what should be kept, where it should be kept, and how it should be stored. This decision making process should lead to a dialog which can build a clear understanding, between employees, of how work should be done. It also instills ownership of the Continue reading
Operations Management
Criteria for a Good Layout
The layout of a plant or facility is concerned with the physical placement of resources such as equipment and storage facilities, which should be designed to facilitate the efficient flow of customers or materials through the manufacturing or service system. The layout design is very important and should be taken very seriously as it can have a significant impact on the cost and efficiency of an operation and can involve substantial investment in time and money. The decisions taken with regards to the facility layout will have a direct influence on how efficiently workers will be able to carry out their jobs, how much and how fast goods can be produced, how difficult it is to automate a system, and how the system in place would be able to respond to any changes with regards to product or service design, product mix, or demand volume. In many operations the installation Continue reading
Method Study Procedure
Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs. So it is the process of analyzing the methods involved in work flow to increase productivity. It deals with doing the work in a better way, with less time and effort. That is why it is also termed as work simplification. Method study procedure is an organized approach and its investigation rests on the following six basic steps: Select the work to be analyzed. Record all facts relating to the existing method. Examine the recorded facts critically but impartially. Develop the most economical method commensurate with plant requirements Install the new method as standard practice. Maintain the new method. The above basic method study procedure was first developed and articulated by Russell Currie at Imperial Chemical Industries (ICI). Continue reading
Receiving and Shipping Function of Materials Management
The principal function of receiving and shipping include deliveries of inbound and outbound freight, inspection, and transfer to and from storage. Efficient processing of materials at these points is essential for effective stock control, production, and customer satisfaction. Receiving takes delivery of inbound shipments and releases and materials to inventory. The major responsibilities include: Control and scheduling of deliveries. Accurate checking and recording of shipments received. Preparation for handling and storage. Whenever possible, deliveries should be scheduled to balance the workload throughout the day. For instance, deliveries from local vendors should be requested for the morning hours so that sufficient personnel and equipment are available for processing outbound shipments, which normally peak later in the day. To plan for receiving activities, supervisors should review information due in from purchase orders, bills of lading, or vendor notices of shipment to determine approximate dates of arrival. This enables Continue reading
Lean Supply Chain Management
Even though Toyota – the Japanese company – was the one who made the lean concept widely well-known with the Toyota production system (TPS), there is a fact shows that lean did not just emerging but it was partially used in the United States. For example in 1908, “Scientific management” made by Frederick W. Taylor was the concept of using scientific method such as standardization to apply with the working process. This scientific idea was criticized to be the initial stage of developing the lean concept, since it helped workers to work in system and ignored the unnecessary jobs. However, Henry Ford is considered to be the first person, who used the lean principles. In 1910, Ford has developed the concept of continuous flow – called Ford’s model T production system (MTPS) – for manufacturing assembly line. This MTPS was to have workers focusing on their individual jobs and moving Continue reading
Intermittent Manufacturing Systems
In Intermittent manufacturing systems, the goods are manufactured specially to fulfill orders made by customers rather than for stock. Here the flow of material is intermittent. Intermittent production systems are those where the production facilities are flexible enough to handle a wide variety of products and sizes. These can be used to manufacture those products where the basic nature of inputs changes with the change in the design of the product and the production process requires continuous adjustments. Considerable storage between operation is required, so that individual operations can be carried out independently for further utilization of men and machines. Examples of intermittent systems are: machine shops, hospitals, general office etc. Characteristics of intermittent manufacturing systems are: Most products are produced in small quantities. Machines and equipment are laid out by process. Workloads are generally unbalanced. Highly skilled operators are required for efficient use of machines and equipment. In-process inventory Continue reading