OPEXSTUDIO
← All examples
Manufacturing / 6S / worked example

A clearer start for every cut order

Make ready stock, offcuts and the next order easy to distinguish.

Take the full example with youPhotos. People. A practical plan.

Project timeline, actions for every S and checks before completion.

Open sample PDF Free to read. No sign-in needed.
Generated illustration: A clearer start for every cut order, starting condition
Generated concept: a possible improved arrangement for A clearer start for every cut order
Starting pointProposed concept
Generated illustrations. The concept shows a possibility, not a completed improvement or verified safety result.

A-grade is the proposed target. A begins at 90% in the existing OPEX rubric. This target uses the same observed criteria and coverage as the sample baseline. It is proposed, not earned from the generated concept; Sustain and other unknowns remain unscored.

Learn it, then try it

Understand the method
behind this example.

Two illustrated lessons with practical steps, a question to try and feedback. Read online or follow the teaching pages in the full report.

A clear starting point

Make the problem
small enough to work on.

Oily floor patches, loose offcuts and mixed stock obscure the saw station’s ready condition. Begin with stock identification, the walking route and the approved return process.

Visible stock staging, tool return and the saw surroundings. Blade selection, guarding, feeds, workholding and technical cutting methods remain with competent authorized owners.

Sample baseline26.3%Sample condition score
Proposed goal90.8%A-grade target

Illustrative starting figures. The goal has not been achieved.

Manufacturing / 6SOPEX field notes

A clearer start for every cut order

Make ready stock, offcuts and the next order easy to distinguish.

Sample starting point26.3%Sample condition score
Goal to work towards90.8%A-grade target
01

See the starting point

02

Picture a better arrangement

03

Test one area

04

Check and repeat

See the starting pointPicture a better arrangementTest one areaCheck and repeat

A worked example to learn from. Sample figures and people; targets are not achieved results.

People, timing and a clear finish

A plan the team can follow.

Read the full report ↗

Project completion timeline

Planned finish · Day 30
  1. Define ready stockNia · Line lead

    Day 1–7 · Separate identified stock, awaiting-review lengths and approved scrap decisions.

  2. Restore the work zoneLeo · Maintenance lead

    Day 8–14 · Leo records the residue-source investigation, authorized correction and real recurrence check; verify the storage arrangement too.

  3. Practice the returnRiya · Shift trainer

    Day 15–21 · Two shifts demonstrate stock identification, return and a missing-label response.

  4. Check the next ordersSam · Quality lead

    Day 22–30 · Repeat fifteen comparable order preparations and retain the complete result set.

Proposed timing and fictional owners. Close each action after its check is met; a date alone does not prove completion.

Actions for each S

Planned finish · Day 30
  1. SortSeparate stock and offcutsNia · Line lead

    Identify required stock, reusable offcuts and scrap through the line lead; preserve stock grade and traceability.

    Day 1–7 · Every retained length has an identity and intended use; scrap cannot be mistaken for released material.

  2. Set in orderArrange supported stockLeo · Maintenance lead

    Trial clear stock and offcut positions while preserving the saw, guards, roller support and outfeed geometry.

    Day 8–10 · The next order can be prepared with the correct stock and existing support throughout handling.

  3. ShineCorrect coolant recurrenceLeo · Maintenance lead

    Maintenance investigates coolant and oil at the base, makes the approved correction and checks following operating cycles.

    Day 8–14 · The source and follow-up check are recorded; wiping away coolant alone does not close the issue.

  4. StandardizeAgree the order-ready resetRiya · Shift trainer

    Document accepted stock identity, offcut return and area-reset checks with the line lead.

    Day 15–17 · The receiving shift uses the same ready condition and reports missing identity or an abnormal condition.

  5. SustainReview the next cut ordersSam · Quality lead

    Track stock-ready time, offcut returns and recurring coolant across comparable orders through day 30.

    Day 18–30 · The final review includes preparation time, quality checks and unresolved actions.

  6. SafetyKeep saw controls effectiveNia · Line lead

    The competent line lead reviews guarding, stock support, handling and required isolation before any rearrangement.

    Day 1–30 · Approved saw controls and material support remain in place; the concept cannot authorize operating changes.

Proposed timing and fictional owners. Close each action after its check is met; a date alone does not prove completion.

Bring the idea back to your work

Start the conversation with your team.

Use the report to choose one area, name the next action and agree how you will check it. Try a photo from your own workplace, then turn the possibility into a practical plan.

Keep exploring

Another useful starting point.

See every example →