The Implementation of Lean Manufacturing - 5S Case Study
Aster Interim Solutions were engaged by Axis Electronics Ltd to carry
out a review of business activities. In the latter part of 2003, Aster
was given the objective of introducing Lean Manufacturing to the
Bedfordshire based electronics manufacturing company. The objectives of
the project were to generate improvements to enhance customer
satisfaction and to produce a marketing strategy which encompassed the
achievements of the project. The scope would involve training the
senior managers, introducing the project to the workforce and then
leading the implementation of the resulting plan.
Phil Inness, Managing Director of Axis Electronics stated, “We engaged
Aster because we were aware of their expertise in our sector and their
previous experience of the implementation of Lean Manufacturing. We
have been impressed by their approach and their breath of their
knowledge on this subject”.
Initially, Aster carried out a lean manufacturing review on behalf of
Axis Electronics. This involved contacting all customers with a
detailed set of questions which were aimed at determining those
attributes customers most valued and others where if improvements were
made, would yield the greatest return in terms of orders, confidence
and satisfaction. Responses were correlated and a detailed report
prepared. The review provided an insight into ‘best-practise’ in the
sector as well as valuable data for the preparation of the detailed
lean implementation plan.
It was decided to start with a project which would involve the whole of
the company and provide timely and positive gains to initiate the
overall lean project. 5S lean manufacturing or work place organisation was chosen as it
would be relatively quick to implement and provide immediate visual
improvements. A cross functional team made up of three project leaders
was selected. The team members were then trained in the philosophy,
details and concepts of 5S lean manufacturing and how to carry out the audits which would
generate the improvement ideas.
The entire workforce was then briefed by Aster and the projected
initiated in a series of monthly audits, resulting in improvement ideas
which would acted upon on a monthly basis.
Phil Inness commented, “As the project developed we found that by
focussing on a small number of actions every month per department, we
not only achieved our goals but the change crept up on the business in
an incremental manner which was particularly important during a very
busy period for our business”. Following the introduction of 5S , we now
plan to ask Aster to introduce other lean tools to our business”.
Aster has since designed, written and published copies of the first
lean manufacturing newsletter which details one of Axis Electronics’
achievements.
This newsletter forms part of the overall marketing literature now used
by Axis Electronics when in discussion with prospective clients.
Paul Wilson
|
