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Manufacturing 98 ConferenceSeptember 9-16, 1998
A Lean Manufacturing Road Map--Getting There From Here--Gettin
g There From HereThursday, September 10, 1998Thursday, September 10, 1998
Management, #412Management, #412Larry Zimmer
Manufacturing Engineering, Inc.
Manufacturing 98 Conference
September 9-16, 1998
Chicago, Illinois
Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
TODAYS SESSION--DISCUSSION ITEMSTODAYS SESSION--DISCUSSION ITEMS
YOUR OBJECTIVES
LEAN MANUFACTURING
An Overview
Characteristics of a Lean
Process
Comparison to Traditional
Manufacturing
BENEFITS OF LEAN
Summary
An Example--Howit Works
THE JOURNEY --IMPLEMENTING LEAN
People Empowerment /
Continuous Improvement
Skilled Technical Implementation
Risk Reduction
TECHNICAL IMPLEMENTATION
REVISITED
A Roadmap From Here to There
--Getting Started
QUESTIONS
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QUESTION:QUESTION:
WHAT DO YOU WANT TO
ACCOMPLISH?
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Manufacturing 98 ConferenceSeptember 9-16, 1998
LEAN MANUFACTURING
A JOURNEY,
NOT A DESTINATION!
LEAN MANUFACTURING
A JOURNEY,
NOT A DESTINATION!
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Manufacturing 98 ConferenceSeptember 9-16, 1998
LEAN MANUFACTURING--AN OVERVIEWLEAN MANUFACTURING--AN OVERVIEW
q Waste is eliminated through continuous improvement efforts
q Focus is on product value stream, eliminatingnon-value added operations: storage, transportation, inspection
q The lean manufacturing mindset:
-- Concepts, way of thinking not techniques-- Culture not the latest management tool
q Continuous product flow is achieved through:-- Physical rearrangement (e.g., manufacturing cells)-- System structure &control mechanisms
q Single-piece flow / small lot production: achieved through-- Equipment set up time reduction-- Attention to machine maintenance-- Orderly, clean work place
q Pull production /Just-in-time inventory control
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Manufacturing 98 ConferenceSeptember 9-16, 1998
LEAN MANUFACTURING CHARACTERISTICSLEAN MANUFACTURING CHARACTERISTICS
q Processing:
-- A part moves to a production operation,
-- Is processed immediately, and
-- Moves immediately to the next operation
q With short order-to-ship cycles times, production is
based on orders rather than forecasts
q Inventories (RM, WIP, & FG) are minimized
q Quick changeovers of machines & equipment allow
different products to be produced with one-piece flow
insmall batches
q Layout is based on product flow
q Quality of each item is assured during processing Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
TRADITIONAL MANUFACTURING CHARACTERISTICSTRADITIONAL MANUFACTURING CHARACTERISTICSq Production scheduled based on forecast
q Build to inventory
q Large batch sizes
q Layout based on department / function
q Central store room or production floor used for
product stagingq Lot sampling used to check product quality
COMPANIES USING THESE APPROACHES HAVE
OPPORTUNITIES TO MAKE IMPROVEMENTS Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
BENEFITS OF LEAN MANUFACTURING
WHAT IF I TOLD YOU IT IS POSSIBLE TO.WHAT IF I TOLD YOU IT IS POSSIBLE TO.
qDecrease yourmanufacturing cycle timesfrom weeks to days (70% or more)
qReduce your inventories 50% or morewhile increasing your customer service levels
q
Increase capacity 50% or more in your current facilities
qMaintain or increase your throughput while-- Reducing your indirect labor by 50% or more-- Reducing your direct labor by 10% or more
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Manufacturing 98 ConferenceSeptember 9-16, 1998
BENEFITS OF LEAN MANUFACTURING(CONT.)
qImprove your flexibility in reacting to changes in requirements
qAllow more strategic management focus
q Increase shipping and billing frequencies, thus
improving cash flowqBottom-line: IMPROVE NET INCOME
qDo all this with a payback period of SIX MONTHS OR LESS
WHAT IF I TOLD YOU IT IS POSSIBLE TO.WHAT IF I TOLD YOU IT IS POSSIBLE TO.
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LEAN MANUFACTURING--AN EXAMPLELEAN MANUFACTURING--AN EXAMPLE
-- 3 PROCESSES: A, B, C
-- PROCESSING TIME AT EACH = 3.2 MIN./UNIT
BATCH A B C TOTAL
1000 3200 min. 3200 min. 3200 min. 9600 min.
(20 shifts)
10 32 min. 32 min. 32 min. 96 min.
(.2 shifts)
SAVINGS = 19.8 SHIFTSTOTAL INVENTORY = 3000+ parts vs. 30
FIRST PART THROUGH SYSTEM = 6403+ minutes vs. 67+
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HOW IS THIS DONE?HOW IS THIS DONE?
q PEOPLE EMPOWERMENT /
CONTINUOUS IMPROVEMENT
q SKILLED TECHNICAL IMPLEMENTATION
q RISK REDUCTION
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Manufacturing 98 ConferenceSeptember 9-16, 1998
LEAN MANUFACTURING PROCESSLEAN MANUFACTURING PROCESS
WASTE REDUCTION
TRADITIONAL
MANUFACTURING
LEAN
MANUFACTURING
CONTINUOUS IMPROVEMENT
PEOPLE TECHNICAL RISKEMPOWERMENT IMPLEMENTATION REDUCTION
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LEAN MANUFACTURING--
A JOURNEY, NOT A DESTINATION
WASTE REDUCTIONCONTINUOUS IMPROVEMENT
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Manufacturing 98 ConferenceSeptember 9-16, 1998
EMPLOYEE EMPOWERMENTEMPLOYEE EMPOWERMENT
qManagement Philosophy / Priority
q Improvement: Everyones Job
qWork Station / Cell Improvements
qSuggestions / Implementation
qKaizen Improvement Teams
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Manufacturing 98 ConferenceSeptember 9-16, 1998
EMPLOYEE EMPOWERMENTEMPLOYEE EMPOWERMENT(CONT.)(CONT.)
qAndon Control
qGoal: Continuous Improvement
qExtensive Training
-- Lean Concepts
-- Kaizen Approach
-- Empowerment
-- Ongoing Reinforcement
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Manufacturing 98 ConferenceSeptember 9-16, 1998
SKILLED TECHNICAL IMPLEMENTATIONqLean Manufacturing Concepts & Principles
qCellular Manufacturing & Facility Layout
qMaintenance Improvement Programs
qMachine Changeover Time Reduction
qProcess Development
qMaterial Handling Solutions
q Inspection Systems
qManufacturing Process Simulation
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WHY ARE BOTH EMPOWERMENT &WHY ARE BOTH EMPOWERMENT &
SKILLED TECHNICAL IMPLEMENTATIONSKILLED TECHNICAL IMPLEMENTATION
IMPORTANT?IMPORTANT?STUDIES* CONCLUDE:
q Technical implementation of lean yieldssome improvement
q Involvement of manufacturing workers
(empowerment) yields some improvement
q In combination, result is a multiplier effect (i.e.,improvement is greater than the two individually)
* 1.Dynamic Duo, Industry Week Census of
Manufacturers, Dec. 1,1997, p. 42
2. Becoming Lean, Chapter 4, p. 103 Manufacturing Engineering, Inc.
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RISK REDUCTIONRISK REDUCTIONqTime Up Front
--Information Gathering
--Identifying Potential Savings
qRoad Map-- Big Hits First
-- Narrow The Scope
-- Save Time & Capital
qAdditional Facility Time: Training / Working With People-- To Assure Results
qComputer Simulation
-- Predict Performance Before Implementation Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
RISK REDUCTION (CONT.)RISK REDUCTION (CONT.)
qPhased Implementation
-- For Control & Manageability
qBenchmark Against Others In Industry
qMilestone Reviews
q If You Use Outside Resources:
-- Fixed Contract Pricing
-- Tie Payments To Milestone Completion-- Results Warranty
-- Payback In Six Months Or Less
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Manufacturing 98 ConferenceSeptember 9-16, 1998
qTraining
qValue Engineering / Product Design Analysis
qKaizen Improvement Teams
qPoka-Yoke Methods to Assure Zero Defects
qPre-Automation: Equipping Machines to Detect
Abnormalities & Stop Automatically
CONTINUOUS IMPROVEMENTCONTINUOUS IMPROVEMENT
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Manufacturing 98 ConferenceSeptember 9-16, 1998
SKILLED TECHNICAL IMPLEMENTATION
REVISITED
q Information Gathering / Defining:1). Product Groupings
2). Current Processes3). Lean Process Team
qEmployee Training & Empowerment (Ongoing)
q Initial Team Design Elements1). Finalize Definition Of Current Process Flow2). Process Review (e.g., Matl Handling, Layout,
Maintenance, Quality, Technology Improvements)3). Design Manufacturing Cells / 1-Piece Flow Approach4). Define Maintenance Requirements / Program
5). Machine Set Up Time Reduction Program
A ROAD MAP
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Manufacturing 98 ConferenceSeptember 9-16, 1998
SKILLED TECHNICAL IMPLEMENTATIONREVISITED
A ROAD MAP (CONT.)
q In-Process Design Review
q
Team Refinement Of Design1). Finalize Initial Design Elements (As Needed)2). Simulation3). Work Standardization4). Error-Proofing
5). Update Of Potential SavingsqDesign Review
q Installation
qStart Up / Control Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
SKILLED TECHNICAL IMPLEMENTATIONREVISITED
A ROAD MAP (CONT.)
qContinuation Of Team Design Efforts
1). Small Lot Production2). Just-In-Time Inventory Control / Kanban3). Pull Production
qDesign Reviews
q Installation (Continuation)
qStart Up / Control Of New Elements
GOAL = WASTE ELIMINATION THROUGH
CONTINUOUS IMPROVEMENT Manufacturing Engineering, Inc.
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Manufacturing 98 ConferenceSeptember 9-16, 1998
For additional information, please contact:For additional information, please contact:
Name: Larry Zimmer
Company: Manufacturing Engineering, Inc.
Address: 1145-F Chesapeake Ave.Columbus, Ohio 43212
Phone: 614-487-8985
Fax: 614-487-8799
Email: [email protected]
Web Site Address: www.MfgEng.com
Manufacturing Engineering, Inc.