This is the 30-Inch View

Lean Manufacturing

Web Resource: Got Boondoggle

By Rick Barker, CPE

Rick BarkerI was recently browsing web blogs and found this one simply because of its title; how can you NOT click on a blog with the title “Got Boondoggle”? Checking out a new blog is a bit like opening a present; you have no idea what you might find. This turned out to be an excellent present. There were a number of good posts about Lean as a culture rather than program. As is often the case, nearly all of the discussions of the Lean process could be directly applied to ergonomics efforts. Take, for example, the entry titled “Sometimes the Best Lean Approach is to Just Jump into the Mud.”

Another entry that stood out was a comparison of Lean to the television reality show, The Biggest Loser: To Get Results, You Gotta do the Work.  “No secrets. No magic.”  Indeed.

The blog mixes humor, cultural references, and anecdotes to educate and encourage the need for cultural change to create lasting program success. My primary criticism of this blog is that it appears to be updated only about once per month. But it can boast quality over quantity.



Ergonomics Tips for Lean Events: How Much is Too Little?

By Rick Barker, CPE

During a lean or continuous improvement event, teams often look for ways to reduce the footprint of a workstation. In some cases, this reduction is a measureable goal of the event. Less floor space means lower overhead cost. A smaller footprint can also benefit the employee by reducing the amount of reaching and walking. Although it’s generally a good idea to strive for a smaller workspace, the desire to reduce space can interfere with an operator’s ability to perform the task well and can introduce ergonomic risk factors. For instance, when working at an assembly bench, the operator needs sufficient free space on both sides to accommodate the width of his or her body (or the width of the part), plus sufficient space for arm and tool movements. This requires at least 46” of horizontal space, sometimes more when the part or tool is particularly large.

Other space considerations include:

  • Width of the walk space between machines and/or storage carts (48” minimum)
  • Knee well width (30” minimum) and depth (18” minimum) for seated tasks
  • Space to walk around to the sides of a pallet or box for loading (29” minimum)

Ergonomic design guidelines like these can help teams implement workplace modifications that correspond to human capabilities and limitations, simultaneously maximizing operator safety and productivity. Applying the guidelines during lean events will ensure that the improvements implemented are effective in meeting these goals.



NEM-noBorder
October is designated as National Ergonomics Month by the Human Factors and Ergonomics Society (HFES).  It is a time to generate awareness and give recognition to those who dedicate their livelihoods to improve the safety, performance, and comfort of humans through research, field studies, focus groups, trainings, and workshops.  A number of notable conferences are taking place this month in North  America and Europe to share the results of these efforts with the public. 

  • September 27 – October 1: HFES 54th Annual Meeting, San Francisco, CA
  • October 4-7, 2010 – ACE 41st Annual Conference, Kelowna, BC
  • October 13-15, 2010 – HFES Europe Chapter Annual Conference, Berlin, Germany

To find out more information about National Ergonomics Month, visit www.hfesnem.org.

 

Thanks to Greg Cresswell for contributing this link.



Experienced Material Handling Equipment

Contributed by Miguel Gonzalez from Humantech

Hello everyone,

If ergonomic improvements have stalled at your facility due to budget constraints, we wanted to direct you towards these resources that provide some "experienced" manual material handling equipment.

American Surplus Inc

www.americansurplus.com

(800) 989-7176

1 Noyes Avenue; East Providence, RI 02916

 

SJF Material Handling Equipment

www.sjf.com/specials.html

(320) 485-2824

211 Baker Ave. W; Winsted, MN 55395



October is National Ergonomics Month

NEMlogo
Happy National Ergonomics Month!

Did you know that October is National Ergonomics Month?
Beginning in 2003, the Human Factors and Ergonomics Society (HFES) designated
October to formally recognize the countless hours of research that go into the
ergonomics profession.  The goal is to promote the application of
ergonomics through teaching, learning, networking, service, and fun!

 

Stay in the loop by becoming an HFES member today, or check
out the National Ergonomics Month website at: http://hfesnem.org/

Thanks to Greg Cresswell of Humantech for this post.



Are your improvement initiatives all talk and no action?

Carmine Coyote at Slow Leadership recently highlighted  a blog post by Freek Vermeulen, an Associate Professor of Strategic Management at the London Business School, which pointed out that in reference to management strategies of the past 10-15 years (TQM, Six Sigma, Job Enlargement, etc.)…

"there's little or no hard evidence that they add anything to company performance" and "none of these techniques seemed to have produced any positive benefit on corporate results, despite containing what sometimes looked like little more than basic common sense".

To anyone that has worked for or with large organizations in the last decade, this should not be a surprise. The "flavor of the month" fails for one of two reasons:

  1. the initiative is slow to show results
  2. the initiative is not driven into the culture from the top down

Let me address the slowness factor first. In many situations, these management strategies involve initiation, definition, and completion of projects that may take weeks, months or even years to close. This long lead time, from initiation of the project to the point where tangible improvements are achieved is not cost effective nor does it contribute to a culture of improvement (were you ever sitting in your office and the landscaping crew starting working outside your window? In the beginning its distracting, but eventually it just fades into the background. Compare this to the continual drumbeat of the latest corporate initiative). Front line employees and senior management want the same thing, improvements and improvements now. Simply put, if you did something for weeks or years and you didn't see any results, would your heart be in it?

In terms of creating a culture, we all know what's important to your boss is important to you…the only way these types of initiatives work is when everyone has performance objectives associated with the plan from the top of the organization down to the foot soldiers, and what's more, they all understand their roles. This will not only drive completion of the tasks necessary for the strategy to be successful, but it is also the best way to create a culture in an organization where one currently does not exist.

A quote from Vermuelen's post really flushes out a key issue:

"Finally the piece-de-resistance: The influence of the adoption of popular management techniques on a CEO's compensation package (salary and bonus)…Yep, you guessed it, and the effects were very strong. If a CEO's firm adopted one of the popular management techniques, his compensation went up."

What Vermuelen found was that the mere appearance of one of these popular programs was enough to give the CEO credibility with investors and the Board of Directors that would merit higher pay. No results, just the effort. Is it any wonder why these programs fail?

Lastly, Carmine Coyote noted, "what all fashionable management fads and techniques seem to have in common is that they promise a quick fix based on a simple recipe"

Unfortunately, too often, the recipe looks a lot better than it actually tastes. All powerpoint, no results.



Employee Engagement is Critical for Change

A recent article on change management in Industry Week (Lean Persuasion) and a subsequent post at Be Excellent (Introducing Change into your Organization) discuss Lean Expert Jamie Flinchbaugh’s suggestions on how to introduce Lean, or other initiatives, to your organization.

The base supposition that employees are resistant to change may be flawed. Actually, most people are naturally resistant to change when the change is made to them, not by them. A key element for successful change is to include people in the process.

Our experience with changing processes (i.e. Lean), altering the workplace and work practices, or changing attitudes and behaviors, has shown that success is primarily dependent upon employee engagement. When people have been included as part of the process that identifies the need for change and are involved in selecting and implementing the necessary actions, they are supportive and many times passionate about change. In turn, they are the best change agents for others.

Planning, communication and ensuring staff are all important. Employee engagement is critical.



5S is not Ergonomics

Broom I am surprised at the increasing number of presentations, discussions, and blog posts using 5S and ergonomics synonymously. As Lean programs begin to realize that good ergonomic design can reduce waste of motion, many people are making a leap assuming they are one in the same. The two are very distinct.

Occupational ergonomics (as defined by the National Institute of Occupational Safety and Health) is "the science of fitting workplace conditions and job demands to the capabilities of the working population. Ergonomics is an approach or solution to deal with a number of problems – among them are work-related musculoskeltal disorders." Simply put: it is designing the job and tools to fit the people doing the work. The science part of fitting is based on using known limits and methods (anthropometry, cognitive limits, static strength, reaction time, etc.) to best design work, tools, job design and flow to fit the capabilities of people.

5S is a method for organizing a workplace to optimize flow. It’s sometimes referred to as a housekeeping methodology; however this characterization can be misleading because organizing a workplace goes beyond housekeeping (see Seiton/Straighten). The key target areas for improvement are workplace morale and efficiency. The assertion of 5S is, by assigning everything a location, time is not wasted by looking for things, and it is quickly obvious when something is missing from its designated location.

The 5S’s (in the original Japanese terms and English equivalents) are:

  • Seiri/Sorting: Going through all tools, parts, and materials in the plant and work area and keeping only essential items. Everything else is stored or discarded.
  • Seiton/Straighten or Set in Order: Focuses on efficiency. When translated to "Straighten or Set in Order", it sounds more like sorting or sweeping, but the intent is to arrange the tools, equipment and parts in a manner that promotes work flow and maximize efficiency.
  • Seiso/Sweeping: Systematic cleaning to keep the workplace clean as well as neat. Daily activity at the end of each shift, the work area is cleaned up and everything is restored to its place, making it easy to know what goes where and to know when everything is where it should be are essential here. The key point is a part of daily work – not an occasional activity initiated when things get too messy.
  • Seiketsu/Standardizing. Standardized work practices or operating in a consistent and standardized fashion. Everyone knows exactly what his or her responsibilities are to keep above 3S’s.
  • Shtisuke/Sustaining: Refers to maintaining and reviewing standards. Once the previous 4 S’s have been established they become the new way to operate.

5S advocates believe the benefits of this methodology come from deciding what should be kept, where it should be kept, and how it should be stored. This decision making process usually comes from a dialog about standardization which builds a clear understanding, between employees, of how work should be done. It also instills ownership of the process in each employee.

5S is a valuable tool for those responsible for improving workplace conditions and this tool becomes even more effective when ergonomic principles are employed BUT it is only one tool and should not be relied upon to solve all ergonomic issues.

Just as you can’t sterilize a hospital room with a broom, the work environment isn’t free from ergonmic risk after 5S.



Efficient+Effective+Effort=Success

Efficient_bagage_2  A post at Slow Leadership caught my attention the other day:

“Why you should think seriously about being less efficient.”  Hmmm.

Though it may seem contradictory to what we know and understand in the world of lean and ergonomics, it makes total sense.  Being efficient is all about minimizing waste, increasing productivity, and decreasing costs (think: “How can I do this with less?”).  Being effective, however, is about finding the right solution and thinking outside of the box (think: “How can we do this better?”)  Now it should go without saying that you need both to be successful; but it’s about how you utilize your resources that counts.

As usual,the 80/20 rule can be applied to various functions within a company:

  • Hourly employees, line managers/supervisors, line engineers, etc.:
    • 80% of the time this group should be encouraged to look for continuous improvement and efficiency gains; this can be done through team-based kaizen events.
    • 20% of the time this group should be encouraged to seek out new methods, tools, and processes; this can be done through involving them in clean-sheet design reviews.
  • Plant management, leadership team, company executives, etc.:
    • 80% of the time this group should be looking for ways to innovate and to be more effective at what they do; this can be done through benchmarking with similar/different industries, market research, etc.
    • 20% of the time this group should be involved in continuous improvement initiatives; this is to ensure there remains a connection to what is currently being done.

Slow Leadership included a statement made by Jeff Bezos, CEO and founder of Amazon.com, on his thoughts about customer needs.  I thought I’d include a couple of other examples of Bezos’ colleagues (who, by the way, also made it onto this year’s Time 100 list who are models of how to be more effective, not just efficient:

  • Indra Nooyi, Chariman and CEO of PepsiCo
    • Rather than just focus on how to be more effective in their traditional market (soft drinks and snack chips), Nooyi pushed for PepsiCo to become a “healthier brand”; purchase Quaker Oats and Tropicana in recent years and removing trans fat from its products well before other competitors.
    • PepsiCo’s international business grew 22% last year
  • Steve Jobs, CEO of Apple
    • Rather than spending time, money, and resources making products people don’t want (think back to the days of the good ol’ walkman and discman), Jobs is king of marketability.  Knowing your customers’ wants and needs are far more important than building it fast or cheap.
    • Apple’s stock has increased over 70% of the past year.

If you’re still not convinced, let’s close with a quote from Thomas Leonard, founder of CoachVille: “When you’re effective, you are able to accomplish the worthwhile goal you’ve chosen. When you’re efficient, you quickly carry out actions. You won’t be effective, however, unless those actions result in your achieving a meaningful goal.”

Are you efficient, effective or efficiently effective? It makes a difference.



On the floor? Here’s what to look for…

On_the_floor

Jon Miller (Gemba Panta Rei) reminds us that "what you find on the floor tells you a lot". In fact, lean challenges aren’t the only thing you’ll find.

By opening your view to observe not only space (floor) and inanimate objects (wheels, Ohno circles, debris, etc.) but also to the people performing the tasks, you’ll get a much better sense of the barriers to higher productivity. After all, people are the sole source of productivity.

What are you looking for?

  • Excessive reaches
  • Bending and twisting
  • frequent movements that bring people out of their comfortable reach area (30 inches)

It will become evident that lack of casters on carts, materials stored on the floor, obstacles like equipment and debris, and no Ohno circles are often the root cause of their non-value added motions and exposure to injury risk factors (musculoskeletal disorders).

So, what are you waiting for…hit the floor!

Photo credit: 




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