- Resources >
- Case Studies >
- Kato Engineering - 5S Kaizen Blitz
Kato Engineering Uses a 5S Kaizen to Utilize Workspace BetterOur Client
Kato Engineering manufactures and sells a complete line of precision-engineered, AC generators, motor-generator sets and controls for prime, standby, and peak shaving power generation. Based in North Mankato, Minn., Kato Engineering employs 325 people and is a subsidiary of Emerson Electric. They have been in business for more than 77 years and currently operate in a three hundred thousand square foot facility. At that facility, they house their own research and development, design engineering, and purchasing and sales staff. Kato Engineering's generators range in power from 200 kW to 15 MW and can be used anywhere for backup power or primary power. They are a preferred supplier of the U.S. Navy and used on as many as 90 percent of U.S. land drilling rigs. Our client's problemKato has long been an Enterprise Minnesota client; on their lean journey to transform business, reduce waste, and increase efficiencies. As early as 1993, Kato was implementing lean techniques with success. Kato Engineering saw predictions that demand would be increasing for their generators. They planned to respond by boosting production to match demand before it became overwhelming, and they wanted to do it without having to expand into any new space. Realizing that they could better utilize space by addressing the problem of organization on the work floor, Kato Engineering decided to plan a 5S Kaizen Blitz with the help of Enterprise Minnesota. Enterprise Minnesota's Solution? 5S Kaizen Blitz
A Kaizen Blitz is an intensive event that focuses on improving one area of the business. Literally, it means continuous improvement blitz. An organization selects one area to focus on, develops a strategy, and implements changes to improve efficiency. A Kaizen Blitz that focuses on workspace organization uses the 5S system: Sort, Set in Order, Shine, Standardize, and Sustain. The goal of 5S is to gain efficiency through organization and improve communication between those sharing a production resource. Kato Engineering chose a 5S Kaizen Blitz to better utilize current workspace. Typically, companies using this system have been able to increase capacity 15-25 percent without further capital investment. Enterprise Minnesota went to work planning the 5S Kaizen Blitz with Kato Engineering. They mapped out the needed improvements and set to accomplish those goals. Kato Engineering's ResultsKato Engineering chose a team of seven workers that titled themselves the 'Gottel's Devils,' using the last name of their supervisor. They went to work on the Vacuum Pressure Impregnation (VPI) and Oven area of the floor, a particularly messy area that provided insulation for the coils in Kato Engineering's generators. It is an area where there are three chambers, each processing one part at a time. While this meant that the processes were mostly defined, they still had room to improve in organization, orderliness, and cleanliness. Over the Kaizen blitz, the team removed cabinets, tools in duplicate and triplicate, and placed other items in a 'red-tag area' for other parts of the floor to come and take if needed. They organized the workspace by laying down lines on the floor for parking equipment and storage, and replaced old storage racks with new fixtures. After their organization, the new storage took up one-third the space as before the Kaizen blitz. Immediately, the workers began to feel at ease with more room and better organization of their tools and equipment. As new workers to the area were hired, they were immediately taught the organization methods and the improvements have been kept up since the Kaizen. As an added benefit, the Kaizen blitz to the VPI and Oven area helped identify 17 new improvement projects for the team to begin working on - of which, they've already completed 14. Kato Engineering continues to utilize the Kaizen blitz approach successfully and plans do many more in the future. |
|
|
Looking for real improvements to your bottom line? Fill out our
