1. Nortel PP7k – Standard Work on Packaging Area Flextronics Tczew Lean Manufacturing Knowledge Sharing 09.08.2007 Prepared by: Michał Hendrysiak

2. 2 FlexLean – Banish Waste, Create Value. Abstract Kaizen subject: Work Standard on Packaging Area - Nortel PP7k Kaizen goals: Improvement of product flow Reduction of WIP and LT Reduction of space occupied by Packaging area Date: 10.08.2007

3. 3 FlexLean – Banish Waste, Create Value. Kaizen Team Team Łukasz Chojaczyk – Product Engineer Rafał Kajzer – Distributor Anna Otta – Junior Quality Engineer Michał Hendrysiak – Lean/SS

4. 4 FlexLean – Banish Waste, Create Value. Kaizen Targets/Results

5. 5 FlexLean – Banish Waste, Create Value. Kaizen News Paper

6. 6 FlexLean – Banish Waste, Create Value. Kaizen before & after BEFOREAFTER

7. 7 FlexLean – Banish Waste, Create Value. Kaizen before & after BEFOREAFTER FREE SPACE

8. 8 FlexLean – Banish Waste, Create Value. Kaizen before & after BEFOREAFTER

9. 9 FlexLean – Banish Waste, Create Value. Kaizen before & after - comments Kaizen team have: - Reduced LT from 10 hours to 7 hours - Reduced WIP from 120 units to 90 units - Freed up floor space from 28 m2 to 14 m2 - Reached faster material flow - Eliminated needs of usage wooden pallets on production - Eliminated redundant activity of repackaging of empty carton and ready packed products - Gained production equipment (work table, computer, screen) - Worked out new layout for packing area; Main ideas: smooth material flow, short distance, simple transparent process - Defined material flow - Achieved better communication between successive process steps - Designed new trolleys and „fixtures” for product transfer on road between quality and packing and packing and warehouse - Defined new tasks for distributor/packing operator - Defined new rules for OBA inspection transport and communication

10. 10 FlexLean – Banish Waste, Create Value. Kaizen lessons learned and best practice Lessons learned: - Power of team work – big commitment of team’s members, who had many suggestions, not only for improvements at Nortel PP7k Line, - Brain storm - only during team work we can exchange ideas that are at once verified, - Participation of different dept. staff (quality)

11. 11 FlexLean – Banish Waste, Create Value. - To introduce sampling at OBA inspection and EST chamber - Better process L1 visualization - 5S implementation on packing area - Delivery of empty cartons directly on ESD pallets - Integration of 2 work places (packing and distribution work tables) into 1 Suggested actions for future

12. 12 FlexLean – Banish Waste, Create Value. Kaizen summary Kaizen team has identified places with excessive buffers which cause long LT Thanks to small batches flow and layout changes, Kaizen team eliminated a large part of WIP Additional savings: faster material flow and defects detection, better communication, better utilization of shop floor space, elimination of not necessary activities (material repacking), production equipment no longer needed