Today I have attended the Kaizen competition. Actually this kaizen comes from employee suggestion especially shop floor suggestion. This is the fruit of what we spread out this couple of months in the shop floor. Every shop floor including production and maintenance look very excited and spirit of competition start to grow well here.
In the beginning, so many obstacle in the suggestion implementation. Many ideas in the shop floor can not be facilitated well and followed up until those ideas can be implemented. Moreover, many ideas from operators are rejected by managers because those manager don’t understand truly what operators mean by that suggestion. The impact is communication between management and operators are not linked well and growth gab between them. shop floor personnel do not want to give suggestion because they think if they give suggestion, management do not care their ideas and never follow-up it. And the worst part is the operator become not caring about their equipment. Just follow the instruction. If the problem happen just call maintenance, and maintenance will fix it without ever looked for root cause of the problems. And the end, blame each others!
After starting implementation TPM, we see that moral of employee need to raise up. And we start to advocate the ideas and create the system so that operators can easily give suggestion and guide them how to create suggestion. Motivating all shop floor to give suggestion create the spirit to create ideas that can be implemented and do kaizen for that ideas. Months by months the ideas become huge in number. To motivate them we do competition in division level that be attended by top management. We have to select which kaizen have to be presented by the suggester. The result is greater than what we expected. All people become very excited because they can show their ideas. We only allow the idea that already implemented and give good result can be counted in the competition.
Suggestion system is one of the way to generate idea from shop floor. I will talk more how operator can give more ideas and implemented it.
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