(4) fitting the receivers in the receiver plates, and (5) mounting and adjusting side stoppers as per width of coil. Several innovative design changes were made that included using gear rack and gear pinion mechanism for row change, using rectangular spacer and scale on the both side of the machine for easy alignment of back plates, fixing the location of the door plate in door frame to eliminate the possibility of variation and need for readjustment, designing receiver plate with spring, and cam and lever mechanism of locking system for easy insertion of receivers in plate and one touch locking and converting continuous groove in door plates to fixed holes for accurate mounting of side stopper. Additionally, Kaizen work methods improvement included the provision of: (1) numerical scale on both sides of the expander machine to avoid visual judgment error, (2) movable trolley to facilitate accessories transportation, and (3) individual (operator) set of pneumatic tools and side stoppers to avoid waiting and delay.
The success of the LMS application can be attributed in particular to: (1) top management support for LMS philosophy and a commitment for continuous improvement through providing continuous employment [5], job assurance, and resources; (2) formation of LMS team with members from functional departments and appointing lean coordinator and lean associate coordinate for future continuity of the LMS program; (3) provision of necessary orientation and training [4]; and (4) collection of relevant and accurate functional (operational) data for the selected products.
It should be recognized that LMS as a philosophy or concept provides the required environment to reduce waste. However, the design and work methods improvement can only be achieved through systematic engineering analysis that includes work design and work method engineering. For making meaningful improvements, often new approach and innovations are required. To obtain the full cooperation of work force for the continuous improvement, the top management must follow the policy of continuous employment and adapt progressive approach towards business to provide job security to the workforce.