Meat + Poultry - December 2008 - 79

LEAN TIPS

the parts. I encourage finding a more
root cause and taking an in-depth Lean
approach.
First, what is the root problem? In
this case the problem is lost parts. Why
are they lost? Sanitation sprays down
all the parts on stainless steel tables.

During the spraying, small parts are
knocked onto the floor. Sometimes the
small parts are put in a tray for cleaning; however, they are often mixed
in with other nuts, bolts, springs and
washers. So, the problem is the sanitation crew, right? No. The root problem

is that small parts are not appropriately
staged for cleaning and subsequent assembly. In Lean terms, this problem can
best be solved by applying 5S. When
equipment is disassembled, all parts
are placed on a rack, in a designated
position, that can be cleaned without
changing the parts placement. This approach helps sanitation and will certainly save time for operations during
assembly in the morning. Most importantly, 5S can be a permanent fix to the
lost parts problem. It takes more time
initially because the operations team
and sanitation will have to agree how
the parts rack should be designed and
fabricated. Once done, however, the
parts should be ready for assembly.
All of the problems during start-up
require supervision and workers to

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member of

The root problem is
that small parts are
not appropriately
staged for cleaning and
subsequent assembly.
In Lean terms this
problem can best be
solved by applying 5S."
observe, identify, discuss root cause
and take long-term corrective steps.
Lean tools such as 5S, visual factory
and kaizen can help solve start-up
problems and prevent them from reoccurring.
Dr. Glen Miller is Senior Lean Consultant for Performance Essentials Inc. More information can be obtained regarding Lean Manufacturing at www.performanceessentials.com
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MEAT&POULTRY

December 2008

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Meat + Poultry - December 2008

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