Results

  • Kaizen action items completed or on track based on completion date

  • Safety action items completed or on track based on due date

  • OEE performance meeting focused improvement target

  • Jones packer downtime objectives (Plan vs Actual)

Equipment Condition

  • Cleaning Supplies available by machine

  • Cleaning board (Kamishibai) posted by the machine

  • Formal Kamishibai board training have been conducted with all personnel that operate the machine (managers, operators, utility and line leads)

  • Operators can explain the Kamishibai board process and perform activities based on schedule

  • Supervisors can explain the Kamishibai board process and perform activities based on schedule

  • Managers can explain the Kamishibai board process and perform activities based on schedule

  • Use of Kamishibai board is evident and process being followed?

Planned Maintenance System

  • Comprehensive machine inspection has been conducted by technicians (mechanic or vendor) to bring equipment to OEM condition

  • Machine mechanical problems have been repaired and/or replaced worn components

  • PM assessment completed- Manufacturer recommended PM vs Current PM in SAP (PM must include PM description)

  • Supervisor and manager PM task have been integrated and implemented to the system

  • PM one-point lessons created and loaded into SAP (maintenance care pack)

  • PM one-point lessons have been printed and posted near the machine for quick reference

  • Sustainment strategy to dedicate time to execute maintenance task during the defined weekday with management support

  • Use of Go/No Go gauges use to inspect/validate equipment & materials condition

Material best Practices

  • Machine operators trained on "We run only good wraps" (Instructional video)

  • Material Best Practices - Implementation of bookends for wraps proper storage

  • Operator compliance on wraps material handling and storage best practices

  • Audit process implemented and follow for wraps storage

  • Corrective action in place to prevent non-conformance wrap storage conditions (pareto)

Standard Operating Procedures

  • Change over documentation created and available by the machine

  • Machine operation procedure (How to Operate Machine) created and available by the machine
    i.e. start up, run & shutdown procedures

  • Machine trouble shooting documentation created and posted by the machine

Machine Visual Management

  • Changeover set points have been marked in the machine

  • Machine gauges have been marked to quickly understand normal vs abnormal operating conditions

  • Min/Max Levels are set on the machine for fluids

  • Implementation of Lean Daily Management Visual Management Boards

Lean Daily Management

  • Manager can explain the purpose and objectives of the visual management board?

  • Manager can explain the purpose and objectives of the visual management board?

  • Daily Meeting is taking place with involvement of workers

  • Key Performance Metrics Up-to-date

  • Pareto and/or data analysis is available and posted

  • Evidence of root causes analysis is available and posted

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