Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line

It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation.

Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them.

Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.

Table of Contents

1
Commitment to Change 
Chapter Summary
2
The Company Kaizen Program 
Kaizen
Kaizen Events 
Kaizen Program
Create and Communicate the Vision 
Establish the Kaizen Champion
Communication Boards and Newsletters
The Kaizen Governing Committee 
Kaizen Champion 
Plant Manager 
Production Manager
Engineering Manager
Materials Manager
Quality Manager
Facilities/Safety Manager 
Human Resources Manager
Kaizen Team Selection
Team Leader 
Team Members5
Process Engineer 
Quality Engineer 
Facilities/Maintenance Personnel 
Materials Handler 
Line Operators
Management 
Kaizen Event Tracking System 
Kaizen Tracking Worksheet 
Kaizen Event
Team Leader
Team Members 
Date and Length
Strategic Purpose 
Anticipated Results
Preplanning
Estimated Cost
Event Spending 
Actual Results
Action Items
Due Dates for Action Items
Responsible 
Status
Kaizen Monthly Meetings and the Kaizen Event Supply Box
Kaizen Monthly Meeting
Discussion of Open Action Items: 15 Minutes
Discussion of the Last Event's Results: 20 Minutes
Planning Upcoming Events: 30 Minutes
Kaizen Event Supply Box
Chapter Summary
3
The Basics 
The Seven Wastes, 5S, and Standard Work 
The Seven Wastes 
Overproduction 
Wait Time
Transportation
Overprocessing
Inventory 
Motion
Defects/Rejects 
The Eighth Waste
5S 
Sort
Straighten .
Scrub/Shine 
Standardize 
Sustain
Standard Work 
Chapter Summary
4
The Strategic Purpose
Business Metrics 
Productivity 
Floor Space Reduction 
Work Station Reduction
Travel Distance Reduction 
Quality
Work in Process (WIP) and Inventory Reduction
Effective Hours 
Product Volume
Takt Time and Cycle Time 
Takt Time
Cycle Time
Visual Management
Production Control Boards
Weekly 5S Board 
Daily Quality Data
Safety Board
Daily Productivity Board
Takt Monitors
Chapter Summary
Electric Bike - Kaizen Event Preparation
5
Four Weeks to Go 
Select the Area and the Kaizen Team Leader
Order Supplies and Equipment
Antifatigue Mats 
Lift Tables
Tool Balancers or Retractors 
Metal Tubing 
Floor Tape and Laminating Material 
Labels
Parts Racks
Plastic Part Bins 
Workstation and Tower Lights
Miscellaneous Preparation
Time and Motion Studies
Time and Motion Study Rules 
Use a Stopwatch
Use a Time Study Collection Sheet
Document the Tasks and Elements
Capture Every Piece of Work Content 
Involve the Operator 
Conduct the Time Studies 
Capture at Least Eight Samples 
Time All Options
Remove the Highest and Lowest Times and Take
an Average
Time to Begin the Kaizen Event 
Chapter Summary
6
Waste Analysis 
Current State 
Cycle Time versus Takt Time
Equipment Constraints
Changeover Time
Material Optimization 
Waste 
Waste Observation of the Electric Bike Assembly 
Main Assembly Line
Miscellaneous Value-Added and Nonvalue-Added
Work 
Future State 
Chapter Summary
7
Two Weeks to Go 
Select the Kaizen Team Members
Get an Update on Supplies and Equipment 
Miscellaneous Preparation
Line Balancing 
Resource Requirements
Eliminate Nonvalue-Added Work
Balance by Time
Balance by Work Content 
Balance by Material 
Chapter Summary. 
8
One Week to Go 
Gather Current State Statistics 
Meet with the Team Members 
Miscellaneous Preparations . 
Standard Work Sheets 
Main Assembly
Headlight Assembly 
Chapter Summary
The Kaizen Event - The Electric Bike Line
9
Day One 
Kickoff Meeting 
Ground Rules
Be on Time 
No Cell Phones or Pagers 
100% Dedication of the Team
Eat Lunch as a Team
Stay Positive 
Make Decisions and Stay on Schedule 

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