Current Work place Situation:
This case concerns the Seiton system improvements for Jigs and tools, and fixtures stored in the tool cabinet of a sheet metal welding workshop.
It was more than ten years ago that this common use tools cabinet was built in the workshop. There is the appearance of Seiri Seiton but the truth is that it is full of dust on jigs and tools, and fixtures and looks as though they have not been used recently. Things are piled up regardless of direction, shape, or function. The tools which are used daily by workers are left on the racks next to the machinery where each person works.
The common characteristics of workers who don’t take care of their equipment are (1) they don’t do good work, (2) they produce many defects, (3) many breakdowns occur, and (4) they have many unreported injuries . This particular workshop has all of these characteristics, unreported injuries, especially. The workers are always worried that a major accident will occur.
Current conditions for sorting Seiri and taking Seiton:
The jigs and tools, and fixtures used in this workshop are stored in two tool cabinets. One contains items which are currently used. The other contains spare items, jigs and tools and parts and scrap/rejected items.
The cabinet has three shelves. Tools can be laid directly on the shelf and hooks in the wall hold other tools. The middle and lower shelves have tools laid directly on them, but the wall is not used.
There are no set individual place for jigs and tools, and fixtures so they are stored anywhere that is open. This means that they are always placed in different places, in a different position. The next time they are used the tool have to be searched for and then it takes time to take them out. The wrong tool is often obtained. If a tool is positioned badly a worker often grabs the cutting edge and injuries himself.
Obvious Problem: The tools cabinet is used as a closet
1) There are currently no labels indicating the order and direction in which jigs and tools, and fixtures should be stored in the tools cabinet. Items are placed in empty spaces. Their directions are all different, and they have not been cleaned or serviced. This means that searching and looking for a tool is difficult. Finger tips are often injured, or tools slip and fall on feet many times.
2) There is no differentiation for storing or positioning of tools which are used on all machinery and specialized tools. Tools are used mistakenly and defects produced.
3) There are no signs indicating that tool should be categorized and stored according to size, weight, and age.
4) There are no signs indicting Seiri Seiton rules. The Seiri system does not help out the Seiton system and tools are taken out mistakenly.
5) Here is no method of separating jigs and tools, and fixtures which need repairs or servicing and no method of keeping a record of them. Tools which have not been repaired are used and defects are produced.
You can probably imagine that because of poor Seiri storage as well as withdrawal Seiton much loss is incurred. The occurring losses were investigated.
Occurring losses: Much time is spent searching and actual production time is reduced costs due to defects and accidents are incurred.
1) Even senior workers spend much time searching.
2) Time losses occur because the wrong jigs, tools and fixtures are used.
3) Injuries must receive medical treatments which takes time and costs money.
4) When tool is not returned to the cabinet, the purchasing procedures, which take time, must be followed. Waiting time cuts into production tome, and there is loss because stock builds up.
5) There are monetary and time losses when the wrong jigs and tools, and fixtures are used, a defect is produced and repair and re-processing has to be done.
6) Here are monetary and time losses when un-repaired or old pieces of jigs and tools, and fixtures are used, a defect is produced, and repair and re-processing has to be done.
7) Preceding and subsequent processes anticipate production delay and defects, and unfinished products pile up.
The above would appear to generate a great deal of loss. Improvements must be made quickly. The causes of the loss were identified and the quantum of loss determined.
After the above the concerned supervisor and workers in the department have made the improvements eliminating the losses and restoring order in Jigs and Tools storage.