intro to lean thinking - virginia...
TRANSCRIPT
Intro to Lean Thinking
What is Lean?• Creating more value for customers with fewer resources.
• A systematic method for eliminating waste.
• A production system.
• A continuous improvement methodology.
• A management system and philosophy.
• ALL OF THE ABOVE
History of Lean and TPS
Taiichi Ohno – began Toyota Production System (TPS)◦ Post WWII, needed to compete with Ford and
U.S.◦ Needed to turn cash quickly.◦ Japan demand too low to support mass
production.◦ Core principle: One-piece flow
Lean Philosophy
“All we are doing is looking at a timeline, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing that time line by removing non-value-added wastes.”
Taiichi OhnoToyota Production SystemBeyond Large-Scale Production,Ohno, 1988
* Most business process are >90% waste and <10% value added
Defining Value
After
Before
Lead Time
Work…Value Added Time
Waste…Non-value Added Time
Value-added Process◦ Those activities that are important to the customer.◦ Activities required by law or ordinance.
House of Toyota
Foundation: Stable Operations
Pillars: Guiding principles
Roof: Overall goal
Center: Workforce and Culture
Lean Thinking and ConceptsContinuous Improvement◦ “Kaizen” – Change for the good◦ “Green and Growing” or “Ripe and Rotting”
Lean Thinking and ConceptsCustomer Centric and Customer Value◦ What does the customer value?◦ What’s best for the customer?◦ Applies to internal and external customers.
Lean Thinking and ConceptsQuality◦ Never pass a defect downstream!◦ Rework, inspections, “return to sender”
◦ “Jidoka” – Automation with human intelligence◦ “Poka Yoke” – Error-proofing
Lean Thinking and ConceptsFlow◦ Keeping the “tubes” moving.◦ Parts, Permits, Patients, etc.◦ Just-in-Time, 1-Piece flow
Lean Thinking and Concepts
7
1
4
6
3
28
5
8
7
52 4
3
1 6
Lean Thinking and ConceptsRespect for People◦ “What’s the root cause?” vs. “Who’s to blame?”◦ Training and Development◦ Servant Leadership◦ Supplier partnerships◦ Valuing everyone’s ideas and skills
7 Types of Waste
Transportation
Inventory
Motion
Waiting
Over-processing
Over-production
Defects
Remember “TIM WOOD”
5S5S is a tool for waste elimination
Used to ensure that the workplace contains only WHAT is needed, WHEN it is needed, and WHERE it is needed.
Helps detect abnormalities at a glance.
Sort – Straighten – Shine – Standardize - Sustain
Value Stream Mapping
KanbanKanban – means “signal” or “card”
An inventory control system to manage the supply chain
Idea originated from supermarketsBased on pull
No action is taken unless signaled from downstream (must give “permission” to take action upstream)
