Professional Documents
Culture Documents
GEMBA @
MGSL
THANKS TO ASHOK
LEYLAND BY MGSL
MGSL is hearty thankful to Ashok Leyland for
giving the Mission Gemba which helps us in
improving productivity and quality of our product.
Buses
Truck Load Bodies
Containers
Tippers
Trailers
Tankers
Petroleum Storage Tanks
Ambulance
Mobile ATM etc.
Manufacture
PLANT LAYOUT
STEP BY STEP
PROGRESS OF
GEMBA
ZONES LIST
1.Machine shop
2.KIT SECTION-1
3.CTTP/FET FABRICATION AREA
4.TOOL ROOM/ DOOR FABRICATION AREA/ KIT SECTION-2
5.FVDP FABRICATION AREA
6.TRANSFORMER RADIATOR
7.PAINT/ COMPRESSOR ROOM/BLASTING BOOTH
8.STORES / HYDRAULIC KIT AREA /RAW MATERIAL
STORAGE
9.OFFICE AREA
10.
MAINTENANCE ROOM
11.
CABIN FABRICATION AREA
12.
RAILWAY (LOCOMOTIVE)
13.
CAFETERIA/WASHROOMS
14.
GENERAL FABRICATION AREA/PRESS SHOP
GEMBA
COMMUNICATION
CENTER
BENEFITS OF GEMBA
We have reduced our Rejection, and
rework.
We got better productivity and
delivery.
Through Problem solving board, we
have identified 20 concerns and out
of these 15 were completed.
1S ACTIVITY IN
VARIOUS ZONES
OF MGSL
WHAT IS 1S?
This activity involves systematic sorting out,
labeling and removal of all items not
needed in the work area so that only the
needed items remain.
Objective: Clutter reduction by clearly distinguishing
between what is needed and to be kept and
what is unneeded and to be discarded.
Red Tagging
Local storage area for a predetermined amount of time
Central storage area for a predetermined amount of
time
Throw away
ENTRANCE
BEFORE
AFTER
MACHINE SHOP
BEFORE
AFTER
AFTER
DEPARTMENTS INTIATED
RED TAG
S No.
Department
Item
Recovered
Value
Disposal
Action
Trailer Mounting
&Accessories
Transferred to
other unit
2.
Sold out
3.
Under
Repairement
Scrapped
Kit Section
Scrapped
Maintenance
7.
Production
8.
Maintenance
Motor 2 HP
9.
Maintenance
1.
Stores
Maintenance
4.
5.
6.
Wiper Motor
Sold out
Sold out
Sold Out
Sold Out
50
20
41
15
30
10
20
10
0
5
Tag PutsTag Removed
0
Dec'11
Jan'12
Feb'12
Mar'12
2S ACTIVITY IN
VARIOUS ZONES OF
MGSL
WHAT IS 2S?
This activity involves developing a place
for everything and labeling it so that it
can be found quickly and put away when
not in use.
Objective: To ensure everything has a place, and
there is a place for everything needed.
Motion Economy
Layout maps
Sign boards
Outlines
Color Codes
BEFORE
AFTER
2S IN PRODUCTION
OFFICE
AFTER
AFTER
SWITCH IDENTIFICATION
IN OFFICE
TOOL ROOM
GUARD ROOM
THANK YOU