Kaizen Tip No. 5: Limit the height of inventory stored in the process

Like in the kaizen tip no.4 we have the problem with visibility. An operator could not see what happen on the line before his place, foreman does not see if line is working or not. Engineers, supervisors or managers cannot understand if production is running smoothly or not. The reason is material is stored up to two meters.


On the second line they set up "MAX HEIGHT" policy and installed simple "MAX HEIGHT" signs hanging from the ceiling.
It is easy to see the process from the begonning to the end. Easy to see any problem, easy to understand the situation for all.

Define maximum height and set up simple signs to help people understand what is within the limit and what is over the limit.
Usually about 150cm is used as the "max height" limit.