OCG Chicago: Kaizen Event
Small Turning (Mazak)
July , 2013
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Kaizen Event Goals
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5S audit score improvement (100%)
S/U reduction (List opportunities only)
Productivity improvement (30%)
Floor space reduction (10%)
Safety / Ergo improvements (4+)
Standard work (5S checklist)
Quality improvement (1)
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Kaizen Event Team
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Kaizen Event Team
• Chris Boudreau – Event Sponsor
• Nick Charbonnier – Team Leader
• Terry Miller – Team Sub-Leader
• Cesar Lopez – Team member
• Rico Walton – Team member
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Lean Team Training
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Pre-project 5S Score: 1.25 S
Total Possible = 60 Points
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Pre-project state: Pic
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Mazak Current State
Unused rack, plastic
hanging, improper outlet
use, wires & hoses
Storage on top of machines,
tables have unneeded items,
no labels, etc.
Bars & rods improperly
stored and not labeled.
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Mazak Current State
Drill press not needed & parts
missing label ID
Unsafe table & unneeded items.
Various unnecessary items
including skid of old jaws…
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RED Tagging: Remove unnecessary items
Out of service machine & jaws
Drill press & unsafe table
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Kaizen Newspaper (Action list)
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Lean Team Hard at Work
Moving,
Cleaning,
Painting,
Organizing
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Lean Team Hard at Work
Moving out obsolete
equipment.
Cleaning, Painting,
racks & tables
Standardized BLUE color
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Improvements
Added Eye Wash station.
Changed 2-socket outlet
to 4-socket to eliminate
improper adapters
Cleaned machine, drilled hole in
cover and replaced onto machine.
Replaced air hoses running on floor to
hard piped air supply and coil hose.
Fixed loose machine gages
and hanging cover.
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More improvements
Cleaned, painted and labeled bar
storage rack.
Chip barrel on wheeled cart unblocks back of machine
access and easier to move. Added material boxes on
floor and replaced anti-fatigue mats
Moved machine created raw material staging
area and cleared walking aisles.
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More improvements
Painted walls & posts according
to OCG standard, labeled
shelving and repaired water hose
reel.
Non-Conforming part box
More Labels
Added Fire Extinguisher
Safety stripping
Cleared walking aisles.
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NVA Time Study (unload / load part)
& Improvements: Chip rake above door
Air gun/hose hanging at “Point of Use”.
Raw part ready at machine.
NVA Time: 36, 48, 44, 53 --> Avg. = 45 Seconds
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Pre-project state: Pic
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Post-project state: Pic
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Post-project 5S Score: 3.42 S
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Sustain: Daily 5S Checklist
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Kaizen Achievements
• Productivity improvement (NVA time reduction) by 62%
– Raw parts ready at machine, air hose hanger location & chip raking.
• Set up improvement. Setup time delay list was developed by
the team and will be addressed separately.
– Replaced missing micrometers and allocated storage space within the
work area. (setup time delay)
– Adding bore gages to the work cell area. (setup time delay)
• 16 % Floor space reduction: Removed old machine and moved
storage cabinet to create new space for raw material. (freed
up 81 of 500 Sq. Ft.)
• Improved 1 quality issue: I.D. oversize problem has many
potential root causes, but the primaries were addressed.
Bore gages available in work area, Adding a “G” identifier on
the part drawing to clarify when grinding stock is required,
etc.
• 8 safety items, 100% complete. Opening up a walking aisle in
work area makes for a safer environment.
• Created Daily 5S check-sheet for Small Turn – Mazak area
• Improved 5S score from 1.25 to 3.42 (137 %).
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30 Day Follow-up Tasks
• Purchase missing micrometers. (Terry)
• Organize & issue dial bore gages. (Terry)
• Receive & issue RED non-conforming
containers. DONE
• Complete new electrical outlet install. DONE
• Install Fire Extinguisher, apply red tape on
floor and paint “Line of Sight” DONE
• Determine other actions relating to Set up
time and ID bore problem issues. (Chris B.)
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Special Thanks to:
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Danny Lyons
Dennis Koukounaras
Stanley Konopka
Pete Rygula
Miguel (Papo) Cortes
Jose Dominguez
• And anybody else we forgot. 
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Lessons Learned
• Time to clean and paint walls was too long.
• Most improvements were completed quickly.
• OCG team has enough talent to tackle most any
project.
• Team works well to complete agreed upon &
assigned actions.
• White walls and clean windows are good. 
• Improved 5S level shows other improvement
needs more clearly.
• Improvement breeds excitement and
participation.
• First Kaizen event sets standard for additional
projects.
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