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FLEXO Magazine : November 2008
PLANTS & PROCESSES The Parlin, NJ manufacturing facility for DuPont ran several 5S Kaizens to improve operations in its storage rooms. left over from the production runs, which must be returned to the warehouse. This is probably the case for most companies in the printing and publishing business. Utilizing internal DuPont consultants and a connection to the NJMEP (New Jersey Manufacturing Extension Program), the Parlin site has run several 5S Kaizens to address the problem. Teams have been built around operators, who know the materials and their use better than anyone. Invariably, these people have ideas for improvement and are eager to make changes that will improve the tasks they perform. The “before” and “after” photos show dramatic differences. But the key to holding the gains is the audit process which is imple- mented after the improvement “dust settles.” Here is where first line supervisors have an important role to play. It’s a lot easier to keep an area orderly if issues are resolved on a daily basis rather than al- lowed to accumulate (by benign neglect) for weeks or even months. No one would claim the conditions in the packing materi- The eight “no regrets” activities identified in the FLEXO October article: 1 Value Stream Maps: . . . . . . . . Find your bottlenecks and biggest opportunities for improvement. 2 7 Wastes: Identify and eliminate sources of waste (Defects, Overproduction, Waiting, Not using people, Transport, Inventory, Motion, and Extra processing). 3 5S: Audit to hold the gains after getting your area in order. 4 Visual Workplace: between products. 6 Process Flow: Help employees to focus on what’s critical to the business. 5 SMED: Reduce the time and effort wasted changing Structure your manufacturing process to make the minimum units required to fill customer orders. 7 Uptime Tracking: Keep track of time spent making first-quality product—the rest is wasted time (and money). 8 Lean Training: Get employees some basic training to help them feel comfortable and participate eagerly in all improvement activities. 5 6 F LEXO ABOUT THE AUTHOR: John J. Morgan has 35 years of expe- rience at DuPont developing and implementing new products and manufacturing processes for synthetic fibers, optical discs, and printing products. Since 1994, he has held various managerial and technical po- sitions in the Cyrel® for Cyrel® Packaging Graphics business. He was project leader AQS, a water-wash flexo plate developed for the envelope and label markets. For the past five years he has engaged in Six Sigma (6s) improvement projects as a Green Belt and Black Belt. Currently, Morgan is a Master Black Belt and Lean Practitioner at the Parlin, NJ, site, which manufactures Cyrel® flexo plates, Teflon® and materials for the electronics industry. NOVEMB E R 20 0 8 www. f l e x o g r a p h y. o r g powders and liquids, als warehouses significantly impact the flexo plates that DuPont customers receive. But all the operators would claim that 5S can make their day easier as they labor to deliver customer orders. This attention to the workplace allows DuPont to make fixed cost productivity improvements. For more info on Cyrel® Packaging Graphics products and ser- vices contact Ray Bodwell at Raymond.W.Bodwell@usa.dupont. com or visit www.cyrel.com. FIND A CHAMPION When you’ve decided to start the journey, make sure you find a champion, and give that champion management’s full and open support. Plan to take advantage of your employees’ knowledge, make use of inexpensive tools, and engage local consultants to get a fast start. Here’s the champion’s action plan: 1 Identify a Lean Practitioner and get him/her some training. 2. Contact your local Manufacturing Extension Partnership . (MEP) and get help identifying opportunities. 3 Engage your workforce and expose its members to some . tools. 4 Pick one (or some) of the eight no regrets actions and “just do it.” . Last, but not least, don’t forget your suppliers—or customers. They might be able to offer help, and this can be a great way to build strong partnerships. ?