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Process Engineering and Innovation Committee Presentation

Explore the key concepts of process engineering and innovation discussed at the Canadian Collision Industry Forum in Mississauga. Learn about waste reduction, 5S methodology, and the benefits of streamlining processes for your business.

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Process Engineering and Innovation Committee Presentation

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  1. Process & Innovation Committee Canadian Collision Industry Forum Mississauga, Ontario January 21, 2006

  2. Committee Members • Ken Friesen, Concours Collision • Tony Canade, Assured Automotive • Bob Dubreuil, Akzo Nobel • Paul McFarlane, The Boyd Group • Mark Bonsor, Dupont • Wayne Riley, Aviva Canada • Neil Anderson, Anderson Consulting • Tom Bissonnette, Parr Auto Body

  3. PROCESS ENGINEERING Your Business Where Do I Start ? • Ken Friesen Process Mapping • Tony Canade’ 7 Types waste • Bob DuBreuil 5 ‘s

  4. Admin Process • Total Days: 32 • Steps 42 • Value 13 Travel • People 1478ft. • Product 524ft. Time • Total 156min. • Non Value 128min. • Value 28min.

  5. Planning Process • Total Days:12 • Steps 54 • Value 5 Travel • People 4029ft. • Product 524ft. Time • Total 131min. • Non Value 94min. • Value 37min.

  6. Production • Total Days:5.5 • Steps 48 • Value 11 Travel • People 8173ft • Product 1524ft Time • Total 684min. • Non Value 113min. • Value 571min

  7. Total • Total Days:19.5-32 • Steps: 144 • Value: 29 Travel • People: 13,680ft 2.6 miles • Product: 2,577ft .5mile Time • Total: 971min. 16.2hrs. • Non Value: 335min. 5.6hrs. • Value: 636min 10.6hrs

  8. Waste - Muda • “Muda” means Waste – specifically any human activity which absorbs resources but creates “no value” to the Customer (insurer, vehicle owner)

  9. 7 Types of Waste • Rework – product or admin. • Overproduction –of goods not needed by next step • Inventories – goods waiting to start or further processing

  10. 7 Types of Waste • People Movement – office/shop • Product Movement – office/shop • Process Time – goods /admin. • Waiting/Sleep Time

  11. What is 5 S? Based on Japanese words that begin with “S”. 5S philosophy focuses on: • Work place organization • Standard Operating Procedures

  12. What is 5 S? • Simplifies the work environment • Reduces waste • Reduces “non-value” activity • Improves quality efficiency • Improves workplace safety

  13. What is 5 S? • Sorting (Seiri) • Set in Order (Seiton) • Scrubbing Clean (Seiso) • Standardizing (Seiketsu) • Sustain (Shitsuke)

  14. Why 5S? • Eliminate waste from uncontrolled processes • Improve delivery consistency • Gain control of equipment, material, and inventory • Improve quality • Improve safety • Improve consistency

  15. # 1 – Sorting • Process to eliminate unnecessary items from the workplace • Tag and evaluate need • Move occasional use items to storage location • Discard unneeded items (scrap etc) • Get rid of “J.I.C.” mentality

  16. Systematic Sorting & Organization • Eliminate space taken up by unneeded items-huge toolboxes, benches, scrap parts • Remove outdated papers and files • Reduce cabinets, shelving, lockers that have no current use • Eliminate outdated posters, wall boards, metrics, slogans, banners

  17. # 2 - Set in Order “A place for everything and everything in its place” • Equipment – shop and office • Tools • Cabinets and files • Brooms and trash cans!!

  18. Sort • Visual Colour System • Work areas (mark on the floor) • Aisle ways • Equipment locations • Storage locations

  19. #3 - Scrubbing Clean • The cleaner the better • Clean areas where red tagged items were removed • Remove dirt, oil, scrap, and garbage • Look at lighting • Clean on a daily basis • Audit the cleaning process • Improve equipment maintenance

  20. Scrubbing Clean • Clean aisles, walkways, floors, machines, desks • Assign cleaning responsibilities • Create target areas: equipment, floors, inventories • Cleaning checklists • Correct deficiencies • Cleaning is a team effort • Correct root cause of messy areas

  21. # 4 - Standardize • Standard Operating Procedures • Implement “SOPs” in all areas • Involve staff in developing “SOPs” • Involve vendors • Involve consultants • Document all SOPS

  22. Standardize Step 1: Planning • Who does what and when Step 2: Allocation • Assign resources to tasks

  23. Standardize • Step 3: Act • Train all employees • Step 4: Implement • Step 5: Verify • Ensure effectiveness

  24. # 5 - Sustain • Most difficult of the 5 S • Employees tend to return to “comfort zone” • Need to monitor and influence until new culture becomes the “status quo” • Takes time!!

  25. Benefits of 5S • Increased efficiency • Increased productivity • Increased profitability • Improved morale • A nicer place to work

  26. Clean is Lean!

  27. “THANK YOU FOR YOUR TIME!!” Please join us in our Breakout Session this Afternoon!!

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