Choosing the right tool from the toolbox-some examples of Gemba Kaizen practice

The author gives an introduction to the Weston EU company, a manufacturing sub-contractor for a variety of different customers in different markets and some of the current product ranges. Two techniques are then introduced: Overall Equipment Effectiveness (OEE) and Set-Up Reduction. Both techniques are described in terms of how they help the company drive improvement in the core of the business-70 capital equipment CNC machines. OEE is discussed first, starting with an explanation of OEE as a process measurement system and how it is used to identify improvements in the use of capital equipment. The reasoning behind the company selecting OEE as an improvement tool is then covered followed by details of the partially successful implementation of OEE in pilot areas. Set-Up Reduction and why it was chosen by the company to help drive improvement is described. The mechanism for carrying out a set-up reduction activity is described in terms of the Kaizen tools used. From that the key elements of internal and external activities are explained and how they are used in conjunction with the Eliminate/Combine/Reduce concept. The key learning points experienced by the company when implementing these techniques are summarised