Kaizen Blitz Paint shop layout - changing the layout to improve safety and workflow Do we try to change people's behaviours, our should we change the situation? A change in the physical work environment can allow the desired behaviours to happen without resistance

1. Kaizen Blitz: Paint Shop Layout
Alan Magner
Wednesday 27th July, 2011
Contact:
alanmagner@variancereduction.com

2. Agenda
1-day event to improve safety & housekeeping in the paint shop
Target
 Improve the housekeeping at the Paint Shop so the Fire Exit will always
be kept clear
Involved
 Mick Norton, Steve Cowling, Mohammed Riyaz
Results
 Fire Exit is kept clear
 Reduced walking distance looking for trolleys, and moving trolleys out
of the way
 All trolleys have a designated place, and are kept in their place

3. Before
After
Problem Statement
Access to the fire exit at the Paint Shop was blocked by trolleys and by inventory
Action
1 day kaizen blitz to improve safety – using 5S principles to improve housekeeping
and improved workflow, and employee engagement to sustain the changes

4. After: Storage for empty disc trolleys
After: Storage for empty trolleys
Problem Statement
 Paint shop has 20 trolleys – not enough room to store them
Action
 Made storage area for 8 disc trolleys that is 5m from the paint shop – used for
trolleys with the low use
 Made storage area in the paint shop for 6 empty trolleys that have high usage

5. After: Storage for painted product
After: Improved visuals & signs
Problem Statement
 When large discs are painted need space to store them – need a space where product won’t
be accidently touched or bumped
Action
 Made storage area for 1 trolley that is 3m from the paint shop – only used for trolleys with
painted product
 Improved visuals - Signs labelling each storage area

6. Before: Residue and dirt on floor
After: Place for inventory to be chromated
Problem Statement
 When picked parts are delivered to the paint shop for chromating, there is no dedicated place for them
 Floor was dirty
Action
 Allocated an inventory square for parts to be delivered to. Enough space between square & chromating
baths to allow easy transfer, pallet “off-square” to allow for a straight drive-in & drop for forklift drivers
 Paint shop floor was swept & mopped, dirt & residue was removed