DMAIC Phase Four - Improve

Documentation Update

 I updated new drafts of the work instructions to a) move work content which had been rebalanced between workstations to the correct work instructions & b) to remove any ambiguity within the work-instructions for the purpose of ensuring that standard methods & techniques are documented. These drafts were processed through the change request process by the Manufacturing Engineer for the line, and approved by the Manufacturing Engineer (ME), Quality Engineer (QE), Manufacturing Training Coordinator & Team Lead.

Standard Work Guidelines

I crated Standard Work Guidelines for each of the workstations on the line documenting the Sequence, WIP levels to me maintained at the workstation, Layout of the workstation.
I processed these documents through the change request process for approval by the ME, QE, Manufacturing Training Coordinator & Team Lead.
Formal training will be documented for all of these updates & changes by the Manufacturing Training Coordinator.

Multiple Activity Charting

Multiple Activity Chart showing existing line design.

I drew up a multiple activity chart showing the first eight stations of the line all of which work in sub batches of five units. The examples shown both reflect the activities taking place during the 4th hour of the shift. I wanted to visually show how the different line designs impacted the flow of the process. I used this tool to show the operators how our newly designed line eliminated long batch set up times & was better balanced resulting in much reduced waiting times - shown below by the much reduced amount of area shaded in red with each cell representing 2.5 minutes.

Multiple Activity Chart showing proposed line design.

The salmon colour shows batch set-up times and the red shows the wait time required by an operator between receiving the next sub batch of five units. This tool was time consuming to put together but very effective in showing the improved design to the operators. Support staff were also impressed with the improvements themselves as well as how effective this tool is at showing the improvements to the line design.