Dr. Rupy Sawhney

Module Week

Fundamentals of Lean Enterprise Systems

1

Designing & Modeling of Lean Systems

2 & 3

Reliability of Lean Systems 3

Analysis of Lean Systems 4

Project-oriented week presentations 5

June 30 July 1 2 3 4 5 6

7

from TYS Airport from TYS Airport

Sunday

Early Check-In Check-in Late Check-in

Monday Tuesday Wednesday Thursday Friday Saturday

Fundamentals of Lean Enterprise Systems (Intro to phylosophy and tools)

(10-11:30)

Foundry 8-12

I-house 1:30 - 3:30

Opening Ceremony

Orientation

(10-11:30)(10-11:30)

(extra cost)

(10-11:30)

UT Transportation

provided

UT Transportation

provided

Dr. Rupy

Sawhney

MS.

Bharadwaj

Venkatesan

Experienced consultants from CIS

Misty DePriest

MS. Enrique

Macias de

Anda

MS. Isaac

Mitchell

You must've heard an old sea story about a ship's Captain who inspected his sailors, and afterward told the first mate that his men smelled bad.

The Captain suggested perhaps it would help if the sailors would change

underwear occasionally. The first mate responded, "Aye, aye sir, I'll see to it immediately!"

The first mate went straight to the sailors berth deck and announced, "The

Captain thinks you guys smell bad and wants you to change your underwear."

He continued, "Pittman, you change with Jones, McCarthy, you change with Witkowski,

and Brown, you change with Schultz."

THE MORAL OF THE STORY: Someone may come along and promise

"Change", but don't count on things smelling any better.

What Does History Teach Us ?

Panhard

&

Levassor

Henry Ford

& GMs Alfred Sloan

Niche

Markets (Aston)

Past Craft Production WWI Mass Production 1960 Lean Production Now

Toyotas Eiji Toyoda

&Taiichi Ohno

Out of business Out of business

Cost increase What do we do?

MARKET COMPETITION

TODAY PRICE OF MP3 Players

COST OF OUR PRODUCT

Fre

iva

lds, A

nd

ris (

20

09

),

Nie

be

ls M

eth

od

s, S

tan

da

rds, a

nd

Wo

rk D

esig

n

12

th E

d. M

cG

raw

Hill

, N

ew

Yo

rk,

U.S

.A.

What if

Cost increase What do we do?

1. INCREASE PRICE AFTER

CRISIS PRICE OF MP3 Players

After increase in price, the possible effects are:

1. Market share loss

2. Sales reduction

3. Profit reduction

2. REDUCE PROFIT

3. REDUCE WASTE

Ben-Hur (1959), http://theworldofjot29.blogspot.com/2012/09/ovp-ben-hur-1959.html

http://www.allempires.com/Forum/forum_posts.asp?TID=30714

Values

Culture

Principles

Your Leadership

Development and

enhancement

of a culture

that provides the

greatest

probability of achieving

the

values of an

organization

Values

Culture

Principles

Your Leadership

Development and

enhancement

of a culture

that provides the

greatest

probability of achieving

the

values of an

organization

Is This Value?

Current Competitive Dimensions:

Value = Quality + Price + Delivery

Value Manufacturing Competitive Dimensions :

Value = Quality + Price + Service + Innovation

What Are The Dimensions On Which Lean

Allows You To Compete?

Cost

Quality

Delivery

Others?

Values

Culture

Principles

Your Leadership

Development and

enhancement

of a culture

that provides the

greatest

probability of achieving

the

values of an

organization

Your Desired Culture is Defined

By What?

Values

Culture

Principles

Your Leadership

Development and

enhancement

of a culture

that provides the

greatest

probability of achieving

the

values of an

organization

Lean Lean focuses on eliminating non-

value added steps and activities in

a process.

Lean makes sure we are working on the right activities.

Lean establishes the value flow as pulled by the customer.

Six Sigma Six Sigma focuses on reducing

variation from the remaining value-

added steps.

Six Sigma makes sure we are doing

the right things right the very first time.

Six Sigma makes the value flow

smoothly without interruption.

Source: Air Academy Associates

A business system that connects and empowers employees to

improve the value of our products

and services to customers by

reducing waste and producing what

is required.

Specify value in the eyes of the

Identify the value stream and

Make at the pull of the customer.

Involve, align and empower .

knowledge in pursuit of

perfection

Waiting

Conveyance

Inventory

Motion

Processing

Employee creativity

Poor quality

Scrap

Rework

Correction

Overproduction

100% inspection

Overtime

Added operations

Increase of variance

Four Pillars

Appropriate Systems

Employees

Capability

Continuous Improvements

Shop Floor Guidelines

IN COMMON SENSE TERMS

LEAN TRAINING

QUESTIONS