Standardizing the Preparation Stand for Equipment Assembly
Before equipment assembly, the preparation stand had to be adjusted according to the dimensions of each equipment. This created unnecessary movement, manual adjustments and material handling during th...
KAIZEN A3 REPORT
Mini Kaizen - Quick Improvement
BEFORE
State before kaizen
- A different table was selected according to equipment dimensions.
- Tables had to be moved manually during preparation.
- Work surface height had to be adjusted manually.
- Unnecessary movement and handling were created during setup.
- The preparation process took approximately 15 minutes.
- 2 operators were required.
- Approximately 30 kg per person had to be handled.
- Workplace safety risk score was 15 — High.
- The existing method created both operational inefficiency and safety risk.
AFTER
State after kaizen
- A standardized preparation stand suitable for different equipment dimensions was introduced.
- One stand can now be used for different equipment sizes.
- Table transportation and replacement were eliminated.
- Manual height adjustment was eliminated.
- The preparation process can be completed by 1 operator.
- Physical load handling was eliminated.
- Preparation time was reduced from 15 minutes to 1 minute.
- Required operators were reduced from 2 to 1.
- Handled load was reduced from 30 kg/person to 0 kg.
- Safety risk score was reduced from 15 to 2.
- Unnecessary movement and adjustment were eliminated.
- The preparation method was standardized.
Problem Statement / Theme
Before equipment assembly, the preparation stand had to be adjusted according to the dimensions of each equipment. This created unnecessary movement, manual adjustments and material handling during the preparation process.
Different tables were selected according to equipment size, and the table had to be moved and adjusted manually. The preparation process took approximately 15 minutes, required 2 operators, and involved handling around 30 kg per person.
A standardized preparation stand was introduced to accommodate different equipment dimensions.
With the new design, one stand can be used for different equipment sizes. Table replacement and manual height adjustment were eliminated, allowing the preparation process to be completed by one operator without physical load handling.
The preparation time was reduced from 15 minutes to 1 minute, while the safety risk score was reduced from 15 to 2.
Reported gain: ₺44,000
Kaizen effect: +₺42,500
Lean principle:
Standardization is not only about making work consistent; it can also remove unnecessary movement, handling and adjustment from the process.
Team Formation
Erdem YILMAZ
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