Continuous Improvement
Wabash Manufacturing Systems
What is Continuous Improvement ?

A continuous process of working towards
achieving incremental gains in the lean
indicators using cross functional teams.

Typical CI tools includes 5S, TPM, Standard
Work, SMED, Variation Reduction, Safety
and Ergonomics analysis, etc…
Lean Indicators and Definitions

Lead Time – the time from customer approval to perform
work to delivery of completed work to the customer

Inventory – the amount of on hand materials needed to
do the job

Floor Space – the amount of space needed to do the job

Productivity - number of labor hours per order

Distance Traveled- the walking distance per cycle
The 4 Tenets of Employee Involvement
1.
Learn By doing
2.
Teach By doing
3.
Use the subject matter experts to obtain ideas
and implement them
4.
By focusing on those adding value, you are
focusing on the customer
The 10 Commandments of Continuous
Improvement
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Abandon fixed ideas.
Think of ways to make it possible.
No excuses needed.
Go for the simple solution, not the perfect o
Correct mistakes right away.
Use your wits, not your wallet.
Problems are opportunities.
Repeat “Why?” five times.
Seek ideas from many people.
There is no end to improvement.
“Profits are made or lost on
the shop floor … plain and
simple.”
-Bill Greubel
President & C.E.O.
5S at Wabash National
A tool and strategy to develop
improvement activities in our
workplace.
What is 5S?
An easy definition is: Finding a place
for everything and putting everything in
its place. 5S is also the beginning
point for continuous improvement (CI).
Lastly, 5S is vital to our jobs and to
Wabash National’s security.
What 5S isn’t . . .

A program

A one time event

Voluntary

Something we tried before

A cleanup to “sell the branch”

Too hard because we are “busy”
Why do we need 5S?
1.
“We must be better today than we were
yesterday, and better tomorrow than we are
today” – Dick Giromini, C.O.O. Wabash
National Corporation
2.
To remain in business we have to accept
change
3.
5S will allow us to reorganize and grow to
be a stronger company
5S is a tool to help eliminate Waste

Transportation – Parts delivered to a standard, mapped
location.

Overproduction – One piece flow.

Motion – Place tools near the point of use.

Defects – Standard Operating Procedures.

Waiting – Balancing operator work.

Inventory – A min/max system to ensure
amount of parts are in the area.

Process – a clean, bright workplace to
remove extra steps in process.
the proper
47
27
30
51
Imagine this
represents your
shop floor, can23you
find number 4?
40
10
58
13
79
62
What does 5S stand for?

Sort (Seiri)

Set In Order (Seiton)

Shine (Seiso)

Standardize (Seiketsu)

Sustain (Shitsuke)
What does SORT mean?
SORT means we remove all items from the workplace
that are not needed for current production (parts, tools,
equipment, etc).
Once we complete the sort process for tools in a work
area, we must develop a standard list of tools that
belong in this area and validate the area is kept free
from non-needed items 30,60 and even 90 days from
the initial sort.
27
30
47
Imagine this
represents your
23
shop floor after
sort, can you find
number404 easier?
10
13
Sort - Before and After
Sort - Before and After
What is SET IN ORDER?
SET IN ORDER means we arrange items so
they are easy to use, and labeling them so they
are easy to find and put away. It begins with
eliminating waste.
Once we set in order for tools, we must
standardize the locations for the tools and audit
to the Set-In Order 30,60 and 90 days from the
initial set in order.
27
30
Imagine this
represents your Part # 9,18,27,36,45
Part # 3,12,21,30,39,48
shop floor after set
23
in order with
labeled racks, can
Part # 2,11,20,29,38,47
47 you find number Part7?# 8,17,26,35,44
40
10
13
Part # 1,10,19,28,37,46
Part # 4,13,22,31,40
Part # 7,16,25,34,43
SET IN ORDER - Example
SET IN ORDER - Example
Set In Order Violations
SET IN ORDER – Before and After
What is SHINE?
SHINE means keeping everything swept and everything
clean. It means keeping everything in top working
condition so that it may be used when it is needed.
Once we shine, we must standardize our housekeeping
requirements and audit to this standard 30, 60 and 90
days from the initial shine
SHINE - Example
SHINE - Example
It takes everyone to succeed!!!
VP of Manufacturing – Jerry Linzey
SHINE
Example of Housekeeping Map
What is STANDARDIZATION?
STANDARDIZATION exists when the first three S’s are
properly maintained. It means we develop methods to
SORT, SET IN ORDER, and SHINE our workplace. It
means we define everything so everyone will know
exactly what we are responsible for; and, exactly when,
where, and, how to do it.
Numbers from 1 to 49
10
13
Imagine this
23
27
represents your
shop floor after
standardize, can
47
you find number 7?
30
40
STANDARDIZE - Examples
What is SUSTAIN?
We SORT areas. We SET IN ORDER
work places. We SHINE areas. With
STANDARDIZATION it is easy to
identify anything out of place.
SUSTAIN is different. It isn’t a single
separate activity. We SUSTAIN when
we have developed habits of always
using the first 4 S’s together on a daily
basis.
27
30
51
62
Imagine this
represents your
shop floor,
40 can you
find
10 which number
58
is missing? 79
23
47
13
Numbers from 1 to 49
Imagine this
represents your
shop floor, can you
23
27
find which number
is missing?
10
13
47
30
40
AREA BEING SUSTAINED
AREA NOT BEING SUSTAINED
What violations do you see?
When does 5S happen?
ALL THE TIME!! 5S is a mindset and
a culture. The 5S’s are a part of each
Associate’s workday. There will also
be CI Events. In an Event, Associates
are taught how to implement the
principles of Continuous Improvement.
How will 5S be implemented?
By the associates! Who has a
better idea to make our jobs easier
than us? Our management is
committed to improving how we
work. We want to work smarter, not
harder. Along the way, support will
come from EVERYONE, including a
CI Team of Associates. We will
teach the 5S process, and together
we will implement it and make it
work.
Who is our 5S Team?

CI Team

Engineering

Safety and Environmental

Maintenance

Human Resources

Shop Floor & Upper Management

YOU!
Benefits to Us & Wabash National

JOB SECURITY!

We get involved in our company

Our jobs become pleasant and satisfying

Obstacles and frustration are removed

We know our expectations
Benefits to Us & Wabash National

Quality will improve

Safety will improve

Costs will be lower

Our reputation will increase

Profits will increase
“Our organization has made significant gains in Safety, Quality and
Productivity. A key enabler to these gains has been improved Workplace
Organization also known as 5S, WPO or simply Housekeeping. The
improved organization means not tripping over parts, being able to find
your tools, having clear aisles, installing the correct parts, etc.
Workplace Organization is critical to our success.”
-Jerry Linzey
VP, Manufacturing and Continuous Improvement
Continuous Improvement Summary






It doesn’t take an expert to implement CI
It is not all about 5S, but 5S is usually a good place to start
Employee Involvement Is CRITICAL to the success of CI.
The employees will buy in quicker when they see the
management team getting dirty too.
Take the lean leap! Try it! If you fail trying to improve, then you
successfully gained knowledge for your next try.
Never stop Improving
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Continuous Improvement - Wabash National Corporation