LEAN Toolbox tactics that APOinc employs

• 6S - One of our favorite and most fundamental tactics is the 6S Kaizen Blitz. We select an area for improvement and create a dramatic change for the better including : Safety, Workplace organization, Standardized processes and documentation, Single Point Lessons (SPL's), and Daily Management Boards with all of the department vital signs and key information on display as a working dashboard.

  LEAN 6S is defined as the cleaning and organization of the workplace in order to create an efficient and safe working environment. The six components of this LEAN “tool” are Sort, Straighten, Shine, Standardize, Sustain and Safety. A 6S project is focused on one area or department and uses a strict methodology to plan, implement and sustain the project and results. LEAN 6S projects are typically 2-3 months in duration, with the climactic event being the execution of the 6S event itself as a Kaizen Blitz, which is typically a 5 day, all-hands overhaul of the affected area based on the previously developed 6S plan.

  • The 6 S's
    1. Sort
    2. Straighten
    3. Shine
    4. Standardize
    5. Sustaion
    6. Safety
  • Learn more about APO, inc. LEAN 6S by clicking here

• Waste Walks and Spaghetti Diagrams - During a Waste Walk, one "becomes" the part or product as you physically walk the path of the process flow at the current state. This path is recorded in several forms, one of which is the Spaghetti diagram.

  Spaghetti Diagrams are a simple process to discover NVA path and effort associated with movement due to poor workflow. This tool is very effective in visualizing the current state and is a precursor to brainstorming and Value Stream Mapping activities.

• Value Stream Mapping - Value Stream Mapping (VSM) is a technique used to analyze and design the flow of materials and information required to bring a product or service to a consumer. The VSM allows for a one page picture of the value stream for a product or service as it flows through the creation process. The goal is to capture and eliminate NVA activities. Identifying NVA time and using the 8 Wastes (DOWNTIME) model:
  • Defects
  • Overproduction
  • Waiting
  • Non-utilized resources/talent
  • Transportation
  • Inventory
  • Motion
  • Excess processing
• Daily Management Boards
• Shopping Markets
• Kan Ban
• Poke Yoke
• Kaizen Strategy Planning - Kaizen or “Continuous Improvement” Events are regularly occurring, focused deployments that requires Team involvement. The key is to take on manageable projects making iterative continuous improvements, while building Team knowledge and confidence. To realize LEAN Transformation, maintain focus and momentum, we will plan to conduct one Kaizen Blitz (4-5 day focused event) per month.
• Single Point Lessons