Compare and Contrast for Continuous Improvement

1. Compare and Contrast for Continuous Improvement

IEE 5200 – Modern Industrial Practices
Instructor – Dr. Tycho Fredericks
Submitted by – Sagar Sable

2. Outlines – Continuous Improvement

1. Tools and Techniques:
• What tool they using?
• Advantages and benefits of these tools?
• On going CIO project ?
2. Impact of Lean Culture:
• The changes occurred after implementation of CIO projects?
• How often they change and modify the process?
3. Training and Skill Improvement:
• When and how often they train their employees?
• How much CIO concepts are practices and in what area?

3. Fabri-Kal

1. Tools and Techniques:
• 5S, Kanban, root-cause analysis.
2. Impact on Lean Culture:
• Productivity increased with 10% every year.
• Runtime percentage, quality runs increases.
3. Training and Skill Improvement:
• Training employees to gain maximum productivity
• Increased customer satisfaction in terms of Quality

4. Steelcase

1. Tools and Techniques:
5s,VSM, Plan-Do-check-Act (PDCA)
PokaYoke(Mistake Proofing), Hiejunka(Mix Modeling).
2. Impact of Lean Culture:
• Help to bridge between system demand and system inventory.
3. Training and Skill Improvement:
• Reduction in manufacturing cost by 1 million previous year .
• Increased customer satisfaction in terms of on-time-delivery.

5. LG chemical Inc.

Tools and Techniques:
Use of 6 sigma Quality improvement technique.
Injury rate reduction. Using OSHA technique.
5s,Kainzen, root-cause analysis.
2. Impact of Lean Culture:
• Efficiency of Quality product production reached to 99.4% .
• Battery quality and life increased .
3. Training and Skill Improvement:
• Increased customer satisfaction in terms of Quality.
• Periodic safety training sessions.
1.

6. Lyon’s Industries

1. Tools and Techniques:
• 5s manufacturing system.
• Jidoka automation technique.
2. Impact of Lean Culture:
• Productivity increased by implementing robotic arms.
• 20 % increase in production and demand.
3. Training and Skill Improvement:
Training employees every month rather than quarterly to gain
maximum productivity.
Increased customer satisfaction in terms of Quality by taking
surveys.

7. Schupan & Sons Inc.

Schupan & Sons Inc.
1. Tools and Techniques:
Use of Kanban inventory management system and JIT
• Using ERP to track demands and orders
2. Impact of Lean Culture:
• Order completion and delivery on time.
• Efficient Demand management .
3. Training and Skill Improvement:
• Training employees about recycling techniques

8. Allnex

1. Tools and Techniques:
They track unintended release of materials to the environment.
2. Impact of Lean Culture:
Goal to reduce all unanticipated emissions to the environment
by 10%, year-on-year.
In 2015, the number of releases to the environment greater
than one pound of material was 4, versus 12 in 2013.
3. Training and Skill Improvement:
Monitoring both leading and lagging indicators, dedicated risk
assessments, gap analysis, training, peer review of
environmental process hazards, and capital investments.

9. Bell’s

1. Tools and Techniques:
Kaizen and KPI (Key performance Index).
• Increased profits and
2. Impact of Lean Culture:
• Productivity is increased (800 barrel)
Building new Logistic and fermentation center.
3. Training and Skill Improvement:
CIO concepts are used to increase productivity in Bell’s
Improving productivity, Efficiency and Quality.

10. Knoll

1. Tools and Techniques:
5s, Pull system, VSM,TQM
Gemba walk everyday morning to improvement In plans.
2. Impact of Lean Culture:
Improvement in delivery time and quality of product.
3. Training and Skill Improvement:
The goal is to encourage teamwork, set ergonomic
guidelines, plan for new technologies or reinvent the office

11. A.C. Foundry

1. Tools and Techniques:
Implemented Standard Work Procedures.
Design of Experiment panel cards are used.
2. Impact of Lean culture:
Optimize waste, efficiencies and reduces the cost.
3. Training and skill improvement:
Green belt six sigma training is provided to the employees.