1. Identify the need or problem for removing waste and creating improved work efficiency. 2. Go to Gemba – a Japanese word that literally means the “real place.” When used in the context of business process improvement, Gemba refers to the place where value is added. In the case of vehicle shops, that is the work areas. 3. Define and document work requirements. Identify the tools and materials required, including how close or far away they are and their frequency of use. 4. Educate workers on why changes are being made and on how to implement and follow the changes. 5. Determine the resources and supplies needed before starting, and who should be involved in the POU process. 6. Develop, with the workers, a prototype. Keep the most frequently used tools and material the easiest to access. Standardize – through diagrams, labels, shadow boards, etc. – where these should be stored to eliminate time wasted searching for items and difficulty in returning them. 7. Test and confirm that the prototype works. Have workers use the POU “station” for several days to see if the arrangement works effectively. Challenge them to make it better. Meet and discuss any additional items needed and potential improvements to functionality. 8. Rework, if necessary, to get it right. 9. Assign accountability. Determine when and how often to reassess in order to continuously improve. 10. Move to the next area that is in need of improvement. THE WHY To capsulize the benefits of the improvements that can be realized by Point of Use, Knapp quotes Shigeo Shingo, a Japanese industrial engineer who helped develop Toyota’s culture of Kaizen: “There are four purposes of improvement: easier, better, faster, cheaper. These four goals appear in the order of priority.” Knapp says “work is going to be easier if we don’t have to walk around to look for tools, materials, supplies and information. Take time to make work easier so it can be done better, faster and cheaper. POU is one way to achieve this in your work environment.” POU doesn’t have to be expensive, notes Knapp. Solutions can be “home grown” and can be applied about anywhere in a vehicle shop to eliminate as many wastes as possible and optimize where necessary. NATIONWIDE WARRANTY COVERAGE FOR UNLIMITED MILES… DuraFit DPFs and DOCs are so durable they come with a nationwide 2-year, unlimited mileage warranty. DESIGNED TO FIT. BUILT TO LAST.™ Toll-free: 1-800-753-3212 www.durafit-exhaust.com/fm DuraFit™ replacement diesel particulate filters (DPFs) and diesel oxidation catalysts (DOCs) pay large dividends in long-term equipment performance and reliability. DuraFit units are exact-fit OEM replacements - engineered and manufactured in the USA for maximum service life. Using innovative catalyst coating, robust designs and stringent testing, DuraFit replacement units provide performance equivalent to, or better than OEM units. Learn more about the DuraFit advantage and our unlimited mileage warranty by calling us at 800-753-3212 or by visiting our website. 2-Year Unlimited Mileage Warranty VehicleServicePros.com/10122947 Cover Story |
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