Training within Industry: The missing link of Lean – Part II

This article is in continuation of the article posted earlier on July 21st which focused on Job Instruction.

Now lets learn more about Job Methods:

Job Methods

A practical plan to help you produce greater quantities of quality products in less time by making the best use of the Manpower, Machines & Materials now available

Step 1 – BREAK DOWN THE JOB

  1. List all details of the job exactly as done in the Current Method.
  2. Be sure details include everything;

          - Material Handling
          - Machine Work
          - Hand Work

Step 2 – QUESTION EVERY DETAIL

1. Use these types of questions;

  • Why is it necessary?
  • What is the Purpose?
  • Where should it be done?
  • When should it be done?
  • Who is the best qualified to do it?
  • How is the ‘best way’ to do it?

2. Question the following at the same time:
Materials, Machines, Equipment, Tools, Product Design, Workplace Layout, Movement, Safety, Housekeeping

Step 3 – DEVELOP THE NEW METHOD

  1. ELIMINATE unnecessary details
  2. COMBINE details when practical
  3. REARRANGE details for the better sequence
  4. SIMPLIFY all necessary details

To make job easier & safer to do;

  • Put materials, tools & equipment in to the best position & within convenient reach for the operator
  • Use gravity feed hoppers or drop delivery chutes whenever possible
  • Make effective use of both hands
  • Use jigs or fixtures instead of hands

     5. Work out your ideas WITH OTHERS
     6. WRITE UP the proposed new method

Step 4 – APPLY THE NEW METHOD

  1. SELL your proposal to the boss
  2. SELL the new method to the operators
  3. Get FINAL APPROVAL of all concerned on Safety, Quality, Quantity, Cost, etc.
  4. PUT the new method TO WORK. Use it until a better way is developed.
  5. Give CREDIT where credit is due.

Acknowledgement:  Courtesy: TWI

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