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Template Process Optimization Check List

This document is a process optimization checklist for a weld shop. It contains 38 check points across categories like waste elimination, poka yoke evaluation, standard operation, TPM and 5S, material flow, and reaction standards. The checklist aims to evaluate the current status of each check point, identify issues or opportunities for improvement, and define recommendations, responsibilities, and targets for supporting required changes. It will be used by a technical team including leaders for lean, production engineering, production, quality assurance, tool room, and maintenance to analyze a weld process and ensure optimal performance.

Uploaded by

Nithiyakumar.P
Copyright
© © All Rights Reserved
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
192 views

Template Process Optimization Check List

This document is a process optimization checklist for a weld shop. It contains 38 check points across categories like waste elimination, poka yoke evaluation, standard operation, TPM and 5S, material flow, and reaction standards. The checklist aims to evaluate the current status of each check point, identify issues or opportunities for improvement, and define recommendations, responsibilities, and targets for supporting required changes. It will be used by a technical team including leaders for lean, production engineering, production, quality assurance, tool room, and maintenance to analyze a weld process and ensure optimal performance.

Uploaded by

Nithiyakumar.P
Copyright
© © All Rights Reserved
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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Shop: Weld Group Leader:

Zone: H79 Team Leader:


Zone: H79 Associate:
OK NG NA
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PROCESS OPTIMIZATION - CHECK LIST V4
Date: Technical Team:-
Loganathan - Lean (Leader)
Dinesh - PED
Xavier - Prodution
Kumaresan - QA
Mani - Tool room
Sakthi - Maintenance
Part No:
Part Name:
Sl.no Check Points
Status
Observations Recommendations Resp. Target
Support
Required
WASTE ELIMINATION
Associate movement/ no.of walk step is reasonable
Operation is done within the Strike zone(within reach of hands)
Associate is not waiting for the part /Mc/ Container
Cycle time of the process matches / within the Engg design cycle time
No additional operations/Over Processing found w.r.to Engg process
design.
Associate has no bending; no stretching; no weight lifting(>15Kg); no
abnormal posture.
Associate is involved for doing process optimzation kaizens recently.
Associate is trained sufficiently in the process
No recent defect outflow from the process to Firewall/Customer.
POKA YOKE EVALUATION
All Failure modes are enlisted specific to the process.
All the Failure modes are addressed by Poka Yoke.
Associate is aware how to inspect each Poka yoke to confirm its
effectiveness.
Each Poka yoke is effective and robust.
STANDARD OPERATION
All Operations in the weld shop have 100% SOP
Associate awareness about Standard Operation is better.
All SOPs are controlled and displayed near to the operators.
SOPs have work instructions, work parameters, standards, quality key
points, safety keypoints and material flow.
Associate does tip dressing properly as per standard.
Associates wear Safety PPE as mentioned in the SOP.
TPM & 5S
TPM Standards are arrived specific to the Jig & machine.
Associate is able to demostrate the TPM check points one by one as
per sheet.
5S Standards are available & associates got trained.
Associate is able to demostrate as per 5S check sheet.
MATERIAL FLOW
Raw Material FG trolleys and Child parts are placed at designated
locations.
No swarf/ debris on the shop floor.
Child Parts/Parts SNP is fixed and been followed
The day production is equal to the day plan given by PPC. (Confirm for
any over production/ under production)
Fixed route for Transportation of Trolleys.
Dedicated Quarantine Area to keep the defective parts is in use.
Each Associate's skill matrix cum training plan is displayed.
Each Line's layout with material IN and OUT flow is displayed.
REACTION STANDARDS
Reaction standard for Defect out flow is available & Practiced
Sweep away standards are clear & awareness among Associates and
Inspectors are better.
Standard for handling Fallen fasteners & fallen parts on the floor.
Reaction standard for Power failure is available & Practiced
Associate is aware about the recent defect outflow & Counter
measures.
Counter measures are effective to avoid recurrence.
Firewall confirms defect outflow and feedback to concerned operator

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