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Welcome to SAI GlobalWelcome to SAI Global
Lean Initiative
SAI Global Improvement Solutions1 300 650 262www.saiglobal.comDonna M DiPalmaMobile: [email protected]
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What is Lean?
Lean is the systematic, continuous elimination of wasteful activities from processes, manufacturing, service or administrative.Lean is Cross Functional & All Inclusive!!!
“A process is a process”
•We need to be relentless in our pursuit of waste
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”Lean” is NOT about manufacturing –it is about
PROCESSES!!!!
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Waste – VA vs NVA
VA – Value add– A value added activity changes the product or
service in fit form or function
NVA – Non Value add– A non-value added activity does not change the
product or service
Waste - ????????
VE – Value Enabling – Inspection; Regulatory Requirements
VA- something customer willing to pay forNWA-does not add valueWaste!VE-Explain•Overproduction-creating inventory•Waiting-for anything-people-material-information-machines•Motion-movement of people, material paper, searching for tools, supplies, computer files•Transportation-movement of any work that does not add value ie: inefficient layout, excessive filing•Overprocessing-extra work customer not willing to pay for•Inventory- takes up space, $$, can become obsolete•Defects- rework, scrap•Resources-underutilization or improper utilization of people- no X-training
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Lean Basics
Process MappingWaste eliminationMistake-proofing-poke yokeKanbanVisual ManagementTAKT time% Loading1 pc flowTreat root cause, “Not Symptoms”5SSet-Up reductionLean measurementTeamwork
Process Mapping-as is by observationWaste elimination-seek out and eliminate 5 whysMistake-proofing-poke yoke-powerpoints and petrol nozzlesKanbanVisual Management-ability to control info about product or service by visuals, signs postersTAKT time-The time you have1 pc flowTreat root cause, “Not Symptoms”get to the origin or source of problem5SSet-Up reductionLean measurementTeamwork-very powerful-energy
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What do we measure?
Lead timesCycle timesError rateTravel distanceSpace (Footprint)HandoffsAuthorizations
Waiting timeMachine down timeResourcesCustomer SatisfactionCustomer complaintsInventoryCarrying costsSpeed to market
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A good beginning….5S
Do the simple things right!
A starting point for any improvement activity
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5S
ScroungeStealStashScrambleSearch
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5S’s
SortSetShine (sweep)Standardize SustainSafety-6S
SeiriSeitonSeisoSeiketsuShitsuke
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Changing the“Culture”
The key to sustaining
•Mindset & behavior•Discuss roadblocks
•Production workers•Office/administrative staff•Middle management
•Sometimes see it as a threat•Sometimes can be territorial
•Culture cannot be changed by just communication & education•This change is realized by practicing & environment•Empowerment of “just do it” attitude
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Core Concepts
The right process will produce the right
results
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Add value to your organization by
developing your people
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ContinuouslyIdentify root cause and
Drive organisationallearning
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By implementing a lean strategy, a company can…..
Reduce costsReduce cycle timeReduce inventoryReduce work-in-process (WIP)Increase capacityImprove lead timesIncrease productivityImprove quality-increase profits
Reduce authorizationsReduce handoffsReduce waiting in in-basketsReduce time to service customerReduce tender response timeReduce bureaucracyReduce paper trailReduce quantity of forms
Fulfil their requirement for CI
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Identify areas of opportunityDecide on area to beginShould be very visibleLean is rapid, quick processHome runs are great!!
butLets begin with Quick wins– Incremental improvements
Low hanging fruit
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5SAwareness & training session for managementAssessment & 2 day blitz – assessment, process redesign and timeline for implementationRepetitive 5 day Lean events – includes 6 hour training and implementation of new processCoachingMentoringGoal – build your internal capabilities!!!