Lean Management applied to Rework Zones

[DOS77]

Hi there everyone,

Its my first post so please bear with any errors on my behalf.

I'm currently doing a project for a company which consists of:

Optimizing two rework zones with no prior optimization, where the company does not know what goes on there because the worker were left to manage those two areas. So the company asked me to try and figure out the flows of products and possibly optimize them as well as optimizing manpower.

I'm currently drawing all the flows of the products but I would like your input on what to do next, some Value Stream Mapping and Spaghetti diagrams? What else?


Thank you for bearing my mistakes and thank you in advance.

Kind regards,
DOS

 

[Marc]

A quick "Bump". My Thanks in advance to anyone who can help with this question.

Suggestions anyone?

 

[DOS77]

Thanks for the bump. I hope more people can see the post and possibly shine some light on my problem

 

[DanteCaspian]

Rework?
First task should be to eliminate rework!
I've had companies want me to do similar projects in work areas... You have to be careful not to get trapped in improving non-value-added tasks!
Put more energy into the more complex task (some will suggest, "impossible") of eliminating of the need for rework.

I say all that however, you may need to spend some time to tidy up, 5S, implement basic standardized work preformed in the rework zones. This can be done to give some sense of stabilization, ensure worker safety, etc. Then the more aggressive tasks must be given focus.
There is no magic to doing this. Find out what the goal is, get a cross functional small team together and work to meet that goal with minimum effort, minimum materials and everything essential... value-added. Understanding the needs, doing VSM and 5S, and including staff to make the change is the way to start. Again, once met, work on the larger scale of elimination. I can't stress that enough.

 

[palmer]

It depends on what the rework is......

In glue or sliced luncheon meats it was worked back into product at a percentage based on what was wrong with the product.

In fabrication, we made the employees responsible fix it immediately if it could be fixed. If it was at the end of their shift they had to fix it before the end of the week. If on Friday, by the end of the following week.

It made a huge difference when the workers (who get extra pay for efficiency) had to fix their own mistakes. We got a lot less rework.

When it has to be worked back into the product someone has to manage it or it doesn't get done.

At least that is my experience in this area.

Also, eliminate rework.......

 

[DOS77]

its a harder case since its in an automotive industry...what do you suggest?

 

[palmer]

It depends on what parameters you have to work with.

I've found that there is a double standard for QA in some environments. If an outside vendor makes the parts and they are not exactly to specs, they approve it. When it was made in house exactly the same way, they rejected it.

There are specs in automotive whether it be nominal, go-no go, etc.... Is the standard too tight to make it productively?

Is the equipment capable of producing to specs? Does slowing the production process down allow the parts to meet specs? Is the equipment capable of producing the product in spec? Is the employee qualified to prdouce the product in spec? Is the person properly trained on the equipment to be able to produce the product in spec?

Like I said, it is wide open and a lot of variables.....

Do a process of elimination either starting at the beginning of the process and working forward or at the end and working your way back to find exactly what is the cause of the issue.

 

[DOS77]

i'm studying two areas specific for rework of vehicles which do not pass required tests

 

[palmer]

You have to find out why they did not pass, what caused the fault, and what caused that until you get to the core problem.

As far as rework, is there a replacement part? Is it inevitable that there will be rework? If it is unusable can it be dsiassembled and parts reused?

Can it be a factory "second"? Where it does not pass spec but is usable and can be used as aftermarket replacement parts?