lean is a business system that focuses on doing only those things that add value to the customer,...
TRANSCRIPT
What is Lean?
Lean is a business system that focuses on doing only those things that add value to the customer, creating continuous one piece flow, and placing a high value on developing people at all levels of the organization.
Brian Hatcher
Improvement Methods
Lean ManufacturingLean Six Sigma
Total Quality ManagementAgile Manufacturing
Toyota Production SystemSix Sigma
Theory of Constraints
PRINCIPLES OF A LEAN OPERATING SYSTEM
Eliminate Waste
Increase Speed & Response
Improve Quality
Reduce Cost
Waste - Muda
Waste is anything that the customer is not willing to pay for.
Necessary Waste - Customer does not want to pay for but is willing to pay for – does not add value to the product
Un-necessary Waste – Does not transform the product – we want to get rid of this waste
7 Wastes in an Organization
TransportationInventoryMotionWaitingOver-
productionOver-
processingDefects
T I M W O O
D
LEAN TOOLS5S
Visual ControlsSMED
Small Batch Single Piece FlowQuality and Continuous
ImprovementTotal Productive MaintenanceManufactured Good Recovery
House of Lean
5 S
Sort - Seiri (Organization)
Set In Order – Seiton (Orderliness)
Shine – Seiso (Cleanliness)
Standardize – seiketsu (Standardized Cleanup)
Sustain - Shitsuke (Discipline)
5 Pillars of the Visual Workplace, Hirano, p. 20, 1995
Visual Controls
SMED – Quick Change
(Single Minute Exchange of Die)
1. Pre – changeover 2. During changeover3. Startup4. After Startup
Increases capacity by creating more available production time.
Single Piece Flow
Make small batches and changeover quickly or single piece flow from pone process to the next.
Value Stream Thinking( From dirt to shelf )
Takt Time =available production time per day
customer demand per day
This is the customer demand for your product or service… the pace at which you must produce.
Value Stream Mapping Workshop, Rother and Shook, p. 71, 2002
Value Stream Mapping Workshop, Rother and Shook, p. 72, 2002
Quality
Advanced Statistical Methods(TQM, Six Sigma)
W. Edwards Deming, Motorola
Zero Quality Control – Quality at the source(Poka Yoke)
Shingeo Shingo
Lean Six Sigma
Define Measure Analyze Improve
Control
Design of Experimentation (DOE)
Kiazen (Continuous Improvement)
Business Process Kiazen (Value Stream)
Kiazen Workshops (5S Event)
Daily Kiazen (Daily Improvement)
The Deming (Shewhart) Cycle
TPM (Total Productive Maintenance) Participation of all employees (not just
maintenance)
Identify problems before they are problems
Correct problems when down time can be planned
Decreases production variablilty
JUST IN TIME SYSTEMS
Pull vs. Push
Inventory Management(Supermarket – Kanban)
Production Management(Level loading – Heijunka)
Manufactured Good Recovery
Managing waste streams
Recycling
