scaling up your operations - investhawaiiscaling up your operations may 4, 2019. hawaii small...

A program of the Hawaii Technology Development Corporation

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A program of the Hawaii Technology Development CorporationA program of the High Technology Development Corporation

Lean Process Improvement for Scaling Up Your Operations

May 4, 2019Hawaii Small Business Fair


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Who am I?

•Wayne Layugan

•Email: [email protected]

•Phone: 808.539.3702



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Who am I?

•Erin Furuichi

•Email: [email protected]

•Phone: 808.539.3621


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Innovate Hawaii• Program of Hawaii Technology

Development Corporation (HTDC)

• Public-private partnership that delivers solutions to U.S. manufacturers

• Training programs

• Manufacturing Assistance

• Advancing manufacturing in Hawaii

Create. Build. Grow.



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What does Lean mean to you?


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Definition of Lean

• relentless removal of wastefulactivities, and

• the simplification & standardization of manufacturing and support processes

A set of principles and practices whichreduce cost through the. . .

. . . throughout the entire enterprise.


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The Value Stream

Non-Value Added ActivityThose activities that take time or resources, but do

not directly contribute to the product/service.

Value Added ActivityAn activity that changes the fit, form, or function, done

right the first time and is something the customer is willing to pay for.


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Define Value Added

Non-Value Added Activity (NVA)Pick an activity. If you STOP doing it now would any customer (internal or external) know the difference. If not, probably NVA.

Value Added Activity (VA)If it’s not clear whether a task is Value Added, imagine what would happen if you STOP doing it. Would your external or end customer complain. If yes… VA.

Non-Value Added but necessaryIf you STOP doing it now, would your internal customer complain? If yes, probably NVA but necessary.


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Common Mistake50% Improvement of VA Time

NVA

VA VA

NVA

Dr. Deming: 94% of the problem is the system, 6% is the people!


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Why Focus on Waste50% Improvement of NVA Time

VANVA

VA

NVA


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Lean – Eliminating the Eight (8) WastesValue Added

Typically 95% of all lead time is non-value added

Non-Value Added • D e f e c t s• O v e r p r o d u c t i o n• W a i t i n g• N o n - u t i l i z e d Ta l e n t

• Tr a n s p o r t a t i o n• I n v e n t o r y• M o t i o n• E x c e s s i v e P r o c e s s i n g


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Lean Applies To…

Product development (Engineering)

Order taking and scheduling

Manufacturing

Logistics

Administrative systems

Human Resources

………..EVERYTHING!

A process is a Process is a Process


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VA vs NVA example

Does the operator have to do all the non-value

added work?

Value – Added

• Blade cuts wood

IncreaseValue-Added

Non - Value – Added

• Handling wood• Clean up• Quality checks• Banding bundles• Moving bundles of wood• Changing blades• Breaks / Lunch• Meetings• Breakdowns• Adjusting saw• Paperwork• Waiting for wood• Waiting for helper to return

wood for additional cut

ReduceNon-Value-Added


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Lean ManufacturingBuilding Blocks

Quick Changeover

Standardized Work

Batch ReductionTeams

Quality at Source

Line Balancing

Visual Controls

Plant Layout

POUS

Cellular/FlowPull System / Kanban

Total Productive Maintenance

ValueStreamMapping

8 Wastes / 5S Systems

Takt Time

Continuous Improvement


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The 5S Systems• Workplace organization method • Developed in Japan

• Seiri (Sort)• Seiton (Set In Order)• Seiso (Shine)• Seiketsu (Standardize)• Shitsuke (Sustain / Self-discipline)

• Technique that enabled Just-In-Time Manufacturing aka Toyota Production System(TPS)

• Foundation for continuous improvement



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The 5S Numbers Company


Orientation• All shifts are 20 sec.• Task is to strikeout

numbers 1 to 49 in correct sequence

Example: 1 2 3…/ / /


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Standardized Work Standard Pig Exercise



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How can a plate of

spaghetti help Lean your process?



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Process Flow – Spaghetti Diagram



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Process Flow – Ideal Layout

• Little to no overlap

L-shaped

S-shaped

U-shaped


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What does Lean mean to you?

Productivity Quality Costs Profitability

+ + =


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Batch Size Reduction

Post It Note Exercise



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Thank you for attending!

[email protected]


mailto:[email protected]

scaling up your operations - investhawaiiscaling up your operations may 4, 2019. hawaii small...

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