LEAN COMMISSIONING CONCEPT

The key to profits in a manufacturing industry is to run on highest possible efficiency. The tools required to reach those ideal efficiency levels are only through imitating the Toyota way also popularly called lean manufacturing system by non-Toyota world.

The application of lean manufacturing had such a profound effect that these practices have now crept into project management systems as well. One of the those Lean Project Management tool is the use of Kanban in commissioning. Kanban works like relay race and establishes a link between two subsequent processes.

What is Commissioning?

Commissioning is part of project handover. Handover signifies the transition of ownership from project team to operation team i.e. production and maintenance. From project team point of view, the handover marks the capitalization of asset and start of Defect Liability Period.

White Kanban (Power On and Quality)

The first step of commissioning is to perform Power On and Quality check. The integral components of this document is to confirm Ohm test, Phase rotation, Voltage Check, Terminal Checks and I marking. This is usually done between Utility, Maintenance and Project team.

Pink Kanban (Built-in Safety Check)

The second step to commissioning of machine is to confirm its built-in safety features like light curtains and safety doors. The equipment must Master Off when safety device is activated. Now one cycle check can be performed. Without Pink Kanban trial activity cannot be started.

Yellow Kanban (Cycle test and Training)

After the successful completion of pink Kanban, machine cyclic trials for quality can be started. Also at this point Skill evaluation of production and maintenance team must be evaluated. At this point the equipment can be used for trial purposes but not for mass production.

Green Kanban (Final handover)

Green Kanban is signed when all Rank A observations and total of 90% punch-list items are closed. It is to be noted that Punchlist is part of C in PDCA cycle. Now the equipment can be used for mass production.

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