First of all, the three made the list of their thoughts and feelings concerning their day-to-day experiences, and they talked them over. They organized these and wrote them up as “Consideration for an Improvement Plan and asked for the opinions of the staff in charge of production technology and production control for the operation process, and the safety control staff. Then they wrote up their improvement implementation policy.
The safety control staff was especially cooperative. The aisles are provided so that those walking through are protected from the facilities and machinery of the workshop. We are required to provide and maintain them. We did not realize the condition of the current situation. If the Factory Inspector made an inspection, we would be held responsible. Please let us cooperate.
(i) Reorganization based on the necessity of the aisle:
1. Guarantee that people walking by will not be exposed to the danger of machinery etc
2. The width of the aisle will not hinder people walking through.
3. Obstructions will not be placed in the area between the floor and up to height of 1.8 meters.
(ii) Space for storing parts necessary for operations will be considered along with the aisle.
(iii) The storage boxes, racks, and tools necessary for operations will be organized.
(iv) Operation methods and the movement of workers in the operations process will be reconsidered and provided for.
(v) The width of the aisle will be considered in conjunction with the space necessary for operations.
(vi) Keeping the aisle clear and delivering parts, etc, will be according to the operations process.
(vii) When the dimensions of the aisles are decided, clear divisions will be made separating it from the workshop floor (usually with yellow lines).
Reorganization Steps to be taken after Improvements are made:
1. Maintain aisles by adding to operations standards (newly developed operations steps) a condition forbidding the placement of anything in the aisles.
2. Do not forget that, although only certain people use the workshop floors, every body uses the aisles.
3. Aisles will not be used for any other purpose.
4. Create a system where, during the times when an aisle must be used temporarily for storage, permission must be received, and a sign stating that such permission has been granted be displayed (as a rule).
Expected Results after Improvements:
Aisles are made to protect the safety of everyone in a factory. Factories which maintain aisles and use them exactly as prescribed usually provide for proper safety measures in all other areas, too. This means that control is maintained in all areas, and consequently, that productivity is high.
Factories which are managed in a careless fashion have no interest in doing anything about aisles.
ML began this project by himself, then was aided by co-workers., his group leader, and finally the staff of connected divisions and sections, with the result that a safe, new space and working environment was attained. This means safety for all working in the factory and a great profit for the factory itself.
The expected results after improvement depends on whether we have been able to reduce the aisle from becoming a storage area and have implemented the improvement policy.
1. If the aisle division lines become unclear or something has been left in the aisle, the person who sees it first should report it to the person in-charge.
2. When the person in-charge is informed, he should immediately redraw the lines or remove the obstructing articles, and then put up a notice stating that a violation has been made.
3. The name of the person in-charge should be written along the aisle line. Inside the aisle, a sign would be posted which says If you notice a violation, please call (write intercom number).
4. The person in-charge will notify the violator (one who breaks rules)
This example teaches us the following points: (1) only the people actually working in a workshop can understand its safety problems, (2) improvements can only be made with the cooperation of a large number of people, and (3) an improved condition can only be maintained by the attitude and actions of the people working in it.