lean manufacturing principles
DESCRIPTION
Lean Manufacturing Principles ManufacturingLEANTRANSCRIPT
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LEAN LEAN MANUFACTURING MANUFACTURING
PRINCIPLESPRINCIPLES
© NCSU IES LEAP Group Rev 3/04
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The Connection North Carolina State University Teaching, Research, Extension and Engagement
College of Engineering
Industrial Extension Service (IES)
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Industrial Extension Service Lean Enterprise Advancement Program (LEAP)
In-plant applications, manufacturing networks, public training, Shingo Prize
Advanced Performance and Standards (APS) FORUMS, QS, ISO, Six Sigma, Project management,
NC Awards for Excellence
Environmental, Health and Safety (EHS) Training, technical assistance, needs assessment in
ISO, HAZWOPER, HAZMAT, ergonomics and industrial hygiene
Energy and Facilities Management Energy usage assessments
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Lean Enterprise Advancement ProgramLean Enterprise Advancement Program
Mission -
Improve the quality, cost and delivery of North Carolina manufacturing firms to improve their competitiveness by understanding and implementing lean enterprise business systems based on TPS model.
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The LEAP mission is accomplished through -
training
facilitation
manufacturing networks
lean assessments
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LEAN THINKING
VALUE - what customers are willing to pay for
VALUE STREAM - the steps that deliver value
FLOW - organizing the Value Stream to be continuous
PULL - responding to downstream customer demand
PERFECTION - relentless continuous improvement (culture)
--- Lean Thinking, Womack and Jones, 1996
Key Principles of Lean Thinking
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Defining Lean
“A systematic approach to identifying and eliminating
waste (non-value added activities) through continuous
improvement by flowing the product at the pull of the
customer in pursuit of perfection.”
The MEP Lean Network
Lean is:
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Lean Goals- TPS “True North”
Zero defects 100% value-add Lot size of one Pull of the customer
TSSC
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LEAN MANUFACTURINGLEAN MANUFACTURINGWhy Become Lean?
•PQCDSM•Improve Customer Satisfaction•Increase Sales and Profits•Insure Long-term Health of Company•Survival•Create Sustainable Competitive Advantage
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Typical Results from Lean Conversions
Lead Time ReductionLead Time Reduction
Productivity IncreaseProductivity Increase
WIP ReductionWIP Reduction
Quality ImprovementQuality Improvement
Space UtilizationSpace Utilization
00 2525 5050 7575 100100Percentage of Benefits AchievedPercentage of Benefits Achieved
FlexibilityFlexibility Skill EnhancementSkill Enhancement Visual ManagementVisual Management
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LEAN MANUFACTURINGLEAN MANUFACTURINGWhere has Lean been successfully implemented?
•ManufacturingAutomotiveIndustrial ProductsFurniture Textiles and ApparelPrinting and PackagingConsumer Products
•Service Industries•Military•Healthcare
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Developing a Lean FactoryDeveloping a Lean FactoryThe Goal and Getting There from Here
•The Goal - Lean Throughout the Entire Enterprise•Set Aggressive Improvement Goals•Measurements of Existing Operations•Recognize Current Problem Areas•Apply the Lean Production System Concepts•Commit to the Continuous Improvement Process•Just do it!
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Value Added/Non-value Added Value-added:
ANY ACTIVITY THAT PHYSICALLY CHANGES THE MATERIAL BEING WORKED ON (not rework/repair!)
Machining Knitting Drilling Spreading/Cutting Assembly Dying Painting Sewing
Non-value added:
ANY ACTIVITY THAT TAKES TIME, MATERIAL, OR SPACE BUT DOES NOT PHYSICALLY CHANGE THE MATERIAL
Sorting Stacking Counting Checking
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8 Wastes Overproduction Excess
inventory Defects Non-value
added processing
Waiting Underutilized
people Excess motion Transportation
Lean = Eliminating the waste
Typically 95% of Total Lead Time is Non-Value Added!!!
Value added
5%
Non-value added
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Value Stream MappingValue Stream MappingA simple diagram of every step involved in the material and information flows needed to bring a product from order to delivery.
Value stream maps can be drawn for different points in time as a way to raise consciousness of opportunities for improvement.
- Lean Lexicon
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- Learning to See
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Lean Production System Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
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Toyota’s Philosophy• Customer first
• People are the most valuable resource
• Kaizen (continuous improvement)
• Shop floor focus
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Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
Lean Production System
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StabilityStabilityThe Four Ms
Operations safely carried out with all task organized in the best known sequence and by using the most effective combination of resources
•huMans•Materials•Methods•Machines
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StabilityStabilityThe 5S’s
•Sort•Keep only what is needed in your area
•Stabilize•A place for everything and everything in its place
•Shine•Clean up the workplace
•Standardize•Develop system (rules) to maintain what has been done
•Sustain•Self discipline to maintain established procedures
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The 5S’s - BeforeStabilityStability
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StabilityStabilityThe 5S’s
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StabilityStability
Courtesy of National Textiles
The 5S’s
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StabilityStabilityVisual Controls
Visual Controls are simple signals that provide an immediate understanding of a situation or condition. They are efficient, self regulating, and worker managed. Examples include:
• Pictures, diagrams • Color coded dies, tools, pallets• Lines on the floor to delineate storage areas, walk ways, work areas, etc.• Improved lighting
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StabilityStabilityVisual Controls
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StabilityStabilityPlant Layout
Raw Stock Q C Receiving
Shipping
Shear Screw Machine
Q CStamp
AssemblyBrake MillLathe
Weld FinishGrind Parts Stock
Drill
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Cellular Layout
Market Demand = 220,000 Units Per YearMarket Demand = 220,000 Units Per YearTakt Time = 27 SecondsTakt Time = 27 Seconds
LatheLathe MillMill MillMill InspectInspectDrillDrill
DrillDrill
TestTestDrillDrillPackPack
11 22 33 44 55
1010 99 88 77
6627 27
SecondsSeconds 27 27 SecondsSeconds
InspectInspect
27 27 SecondsSeconds
StabilityStability
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StabilityStabilityCellular Layout
Courtesy of Duff-Norton, Charlotte, NC
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StabilityStabilityTotal Productive Maintenance
Total Productive Maintenance (TPM) is a series of methods to keep equipment running
The goals of the TPM process include:•Develop people who are equipment-knowledgeable•Create well-engineered equipment: building in safety and quality•Create an environment where enthusiasm and creativity flourish•Maximize equipment productivity and capacity as measured by Overall Equipment Effectiveness (OEE)
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Related Losses
• Setup and Adjustment
• Breakdowns
Related Losses
• Idling and Minor Stoppages
• Reduced Speed
Related Losses
• Startup
• Defects and Rework
OEE = Availability × Performance Efficiency × Rate of Quality
AvailabilityWhen or how often do you lose total availability of your equipment?
How long are your set-ups?
Does your equipment break down frequently?
Performance EfficiencyDoes your equipment start and stop a lot?
Does your equipment run at 100% of its designed speed?
Rate of QualityDo you manufacture quality products?
Are your processes repeatable?
StabilityStability
The Six Big Losses that downgrade Machine Effectiveness:
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Sample Daily Operator PMDaily Operator PM
1. Check coolant level through clear Plexiglas
2.Check heat exchanger fans(strings should be moving)
3.Check servo drive fans (string should be moving)
4.Check heat exchanger air filter(change when dark)
5.Check servo drive air filter(change when dark)
6.Check way lube reservoir(add when low)
7.Check main motor air filter(change when dark)
8.Check main motor cooling fan(string should move)
9.Check mist collector motor and air filter(change when dark)
10.Check bar feeder hydraulic motor air filter
11.Check bar feeder hydraulic oil level(add when low)
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Developing a Lean FactoryDeveloping a Lean FactorySummary – Stability in Manufacturing
Processes
•4Ms•5S•Visual Controls•Plant Layout•Total Productive Maintenance
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Lean Production System Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
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Just-in-TimeJust-in-TimePull System
•Pull System is a flexible and simple method of controlling/balancing the flow of resources.
– Eliminating waste of handling, storage, expediting, obsolescence, repair, rework, facilities, equipment, excess inventory (work-in-process and finished).
•Pull System consists of:– Production based on actual consumption– Small Lots– Low inventories– Management by Sight– Better Communication
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Just-in-TimeJust-in-TimePull System
• Kanban
- A signal to indicate when more parts are needed(Order or Produce)
- Card, empty Bin, In Process Kanban (IPK) on plant floor
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Just-in-TimeJust-in-TimePull System
Courtesy of Ingersoll-Rand Co., Southern Pines, NC
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Just-in-TimeJust-in-Time
• A carton of milk is removed from shelf
•A stock person restocks the empty location, but only brings what shelf can accommodate
•the supermarket combines visual control, pull system, Kanban, 5S
Supermarket Analogy
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Just-in-TimeJust-in-TimeQuick Changeover (Set-up Reduction)
Single Minute Exchange of Dies (SMED)•a series of techniques for changeovers of production machinery in less than ten minutes (single digit minutes)
Set-up Reduction Program Goals•To achieve smaller lots•To maintain consistent quality•To minimize inventory•To reduce lead times•To address frustration of setup personnel
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Identify internal vs. external
changeover tasks
Analyze each task’s real
purpose and function
Focus on no/low cost
solutions
Aim to eliminate
changeover time
Just-in-TimeJust-in-TimeBasic SMED Principles
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Just-in-TimeJust-in-Time
Positioning Pins
Positioning Pins
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No/Low Cost Solution: One-Turn MethodsPear-Shaped Hole Method
Tighten Here
Attach and Remove
Here
Just-in-TimeJust-in-Time
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No/Low Cost Solution: One-Turn Methods
Speed Nut
Just-in-TimeJust-in-Time
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No/Low Cost Solution: One-Turn Methods
Wing Nut Method
Just-in-TimeJust-in-Time
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No/Low Cost Solution: One-Motion Methods
Cam Method
Just-in-TimeJust-in-Time
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Just-in-TimeJust-in-TimeQuick Changeover
Not quick: Must heat molds and plates before changeover
Quicker: Test stand with hot plates to pre-heat molds and plates
Courtesy of Playtex Panama, Santo Domingo, DR
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Just-in-TimeJust-in-TimeContinuous Flow - Batch Size Reduction
•The best batch size is one - one piece flow, or make one and move one!
•Benefits: Reduces WIP, lead time, cycle time, etc. and improves quality
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10 minutes
10 minutes
• Batch & Queue Processing
Lead Time: 30+ minutes for total order21+ minutes for first piece
10 minutes
ProcessA
ProcessB
ProcessC
12 min. for total order3 min. for first part
ProcessB
ProcessA
ProcessC
• Continuous Flow Processing
Just-in-TimeJust-in-Time
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Takt Time = Demand RateTakt Time = Demand Rate
WorkWork Time AvailableTime AvailableNumber of Units SoldNumber of Units Sold
Takt TimeTakt Time = =
GOAL: Produce to Demand
Just-in-TimeJust-in-Time
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Developing a Lean FactoryDeveloping a Lean FactorySummary - Just-in-Time
•Pull Systems/Kanban•Point Of Use Storage•Quick Changeover/Setup Reduction•Continuous Flow•Takt Time
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Lean Production System Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
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JidokaJidokaQuality at the Source
•Source Inspection: Operators must be certain that the product they are passing to the next work station is of acceptable quality.
•Operators must be given the means to perform inspection at the source, before they pass it along.
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JidokaJidokaQuality at the Source
Courtesy Sara Lee Intimate Apparel, Villanueva, Honduras
Source Inspection at Molding
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JidokaJidoka
Courtesy of National Textiles
“Bull’s Eye” for checking package size
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JidokaJidokaQuality at the Source
•Samples or established standards are visible tools that can be used in the cell for such purposes
•Process Documentation defining quality inspection requirements for each work station may need to be developed
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JidokaJidoka
Poka-Yoke (Mistake Proofing)A Poka-yoke device is any mechanism that either prevents a mistake from being made or makes the mistake obvious at a glance.
Poka-yoke devices:- perform well when corrective action involves trying to eliminate oversights and omissions.- can reduce the time and cost of informative inspection to near zero.- used with source inspection, can ensure that proper operating conditions exist prior to actual production.
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JidokaJidokaPoka-Yoke (Mistake Proofing)
Examples: Fueling area of car has three mistake-proofing devices:
1.filling pipe insert keeps larger, leaded-fuel nozzle from being inserted 2.gas cap tether does not allow the motorist to drive off without the cap 3.gas cap is fitted with ratchet to signal proper tightness and prevent over-tightening.
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JidokaJidokaPoka-Yoke (Mistake Proofing)
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JidokaJidokaAndon
A visual management tool that highlights the status of operations in an area
at a single glance and that signals whenever an abnormality occurs.
An andon can indicate production status (for example, which machines are
operating), an abnormality (for example, machine downtime, a quality
problem, tooling faults, operator delays, and material shortages), and needed
actions, such as changeovers. An andon can also be used to display the status
of production in terms of the number of units planned versus actual output.
--- The Lean Lexicon
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JidokaJidokaAndon
Courtesy of Sara Lee Intimate Apparel
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“When I was asked to attend the general manager’s meeting the first time, I was happy to attend because I thought I could say that there were no problems in my department. And I said so when it was my turnto report. Then, this General Manager from Toyota looked straight intomy eyes and said, ‘Steve, when you say you do not have a problem, thatis the problem.’”
At this moment, I realized that in order to succeed in this business, I have to change my way of thinking totally.
--- From JIT Kakumei no Shogeki by Kiyoshi Suzaki, p. 14.
JidokaJidokaIdentifying Problems
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JidokaJidokaIdentifying Problems - Trystorming
Courtesy of National Textiles
Before After
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JidokaJidoka
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Developing a Lean FactoryDeveloping a Lean FactorySummary - Jidoka
•Quality at the Source•Poka Yoke•Andons•Effective Problem Solving
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Lean Production System Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
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StandardizationStandardizationStandardized Work
Establishing precise procedures for each operator’s work in a production process, based on three elements:
1. Takt time, which is the rate at which products must be made in a process in order to meet customer demand.
2. The precise work sequence, in which an operator performs tasks within takt time.
3. The standard inventory, including units in machines, required to keep the process operating smoothly.
--- The Lean Lexicon
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StandardizationStandardization
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StandardizationStandardizationStandard Work Board
Courtesy of Ingersoll-Rand Co., Southern Pines, NC
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Takt Time = 10 seconds
StandardizationStandardization
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Leveling the type and quantity of
production over a fixed period of
time. This enables production to
efficiently meet customer demands
while avoiding batching and
results in minimum inventories,
capital costs, manpower, and
production lead time through the
whole value stream.
StandardizationStandardizationHeijunka
---The Lean Lexicon
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A tool used to level the mix and volume of production by distributing kanban within a facility at fixed intervals. Also called a leveling box.
A load-leveling box has a column of kanban slots for each pitch interval, and a row of kanban slots for each product type.
StandardizationStandardizationHeijunka Box
---Learning to See
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The practice of releasing production instructions to work areas and withdrawing completed product from work areas at a fixed, frequent pace.
In this type of handling system, a material handler, or waterstrider, performs a route through a facility at precisely determined time intervals.
StandardizationStandardizationPaced Withdrawal
---Learning to See
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StandardizationStandardization
Courtesy of Duff-Norton, Charlotte, NC
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The location where a predetermined standard inventory is kept to supply downstream processes.
Supermarkets are ordinarily located near the supplying process to help that process see customer usage and requirements.
StandardizationStandardizationSupermarket
---Learning to See
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Supermarket Pull System
Courtesy of Seamless Textiles, Humacao, PR
StandardizationStandardization
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KaizenContinuous improvement of an entire value stream or an individual process to create more value with less waste.
There are two levels of kaizen (Rother and Shook 1999, p.8):1. System or flow kaizen focusing on the overall
value stream (kaizen for management).2. Process kaizen focusing on individual processes
(kaizen for work teams and team leaders).
- Lean Lexicon
StandardizationStandardization
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Developing a Lean FactoryDeveloping a Lean FactorySummary - Standardization
•Standardized Work•Heijunka/Leveling•Paced Withdrawal•Supermarket•Kaizen
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Lean Production System Goals - highest quality, lowest cost, shortest lead times
Heijunka Standardized Work Kaizen
Just-In-Time•continuous flow•takt time/pace
•pull system•triggers
Jidoka•separate man &
machine work•identify abnormal
conditions•poka yoke
Stable Manufacturing Process
Involvement
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InvolvementInvolvementWorkplace Practices
•Teams–with rotation of highly specified jobs.
•Cross trained and multi-skilled employees–who can work many operations within a cell and even operations in different cells
•Continuous improvement philosophy•Process quality, not inspection•Use of participatory decision making
–Quality Control Circles, team-based problem solving, suggestion systems, etc.
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Keys To Success
Focus on the goal- eliminate waste!
Gather baseline information and measure results
Get everyone involved
Keep it simple
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Reference Materials
• Lean Thinking by Jim Womack and Daniel Jones
• Lean Production Simplified by Pascal Dennis
• Learning to See, Mike Rother, John Shook, The Lean Enterprise Institute, Inc, 1998.
• “Decoding the DNA of the Toyota Production System” by Stephen Spear and H. Kent Bowen, Harvard Business Review, September-October 1999, pp. 96-106
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Lean Enterprise Advancement Program (LEAP)
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