lesson 03 tools
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Lean Management – Tools
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Agenda
5S + 1 Value-Stream Mapping Kaizen, and Kaizen Blitz Takt, Jidoka, Kanban Poka-yoke SMED
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Seiri (Sort) Seiton (Simplify)
Seiso (Sweep) Seiketsu (Standardize)
Shitsuke (Sustain) +
Safety
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Seiri
Sort Necessary vs. unnecessary Right quantity when needed Tagging Cost Example
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Seiton
Set in order Quick access Efficiency Organize/Labeling Frequency of use Visual A place for everything and everything in its place
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Seiso
Clean Mess prevention Shine and check Causal analysis Cleaning schedule Cleanliness campaign
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Seiketsu
Standardization Cleanliness Tools Visual controls Prevention Identical workstations Preventive maintenance Implementation steps
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Shitsuke
Discipline Sustain Habit Rules Tools Standards
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Safety
Uncluttered workplace Well maintained equipment Clean workspace
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5s + 1 Summary
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Safety
Safety
Seiri (Sort): Sort only what is needed where is needed.
Seiton(Simplify): A place for everything and everything in its place.
Seiso (Sweep): Clean the workspace and keep it clean.
Seiketsu (Standardize): Standardize the first three “S.”
Shitsuke (Sustain): Stick to the first 4S.
+ Safety: Provide a safety
environment for everybody.
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Value Stream Mapping
Flow of inventory and information Identify and eliminate waste Value as defined by customer Optimum value Identify value stream Current state Future state
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Kaizen
History of kaizen Continuous improvement Humanize workplace Small improvements Kaizen tools
PDCA cycle 5 Whys Ishikawa
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Plan
Do
Check
Act
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Kaizen Blitz
Kaikaku (Japanese word) Kaizen in short timescale Focused events Rapid improvement Small improvements
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Takt
Takt time Pull scheduling Customers buying rate TAKT time formula Efficiency
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Jidoka
Quality at source Autonomation (Intelligent automation) Required quantity Product defects Process malfunctions Alerting
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Kanban
History Scheduling System for JIT Based on Supermarket Pull System Kanban Cards Three-Bin System Example
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Poka Yoke
History Mistake proofing Defect prevention Three types (Contact, fixed value, motion) Implementation in manufacturing Implementation in service
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SMED
Single-Minute-Exchange of Die History Quick Changeover Less Inventory Improved Flow Examples
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Summary
5S + 1 Value-stream mapping Kaizen, and kaizen blitz Takt, jidoka, kanban Poka-yoke SMED
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Quiz-1
1. What are the 5 phases of 5S? A. Shine, Shut-Up, Sustain, Sort, Standardize B. Sustain, Sort, Standardize, Sushi mi, Shine C. Sort, Set-in-Order, Shine, Standardize, Sustain D. Sort, Sustain, Sushi, Shine, Standardize
2. Red tags are first used in what step of 5S?
A. Set in Order B. Sort C. Standardize D. Separate
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Quiz-2
3. What does PDCA stands for? A. Process Delegating Control Automation B. Plan Do Check Act C. Personal Data Calendar and Assistant D. Prepare, Deliver, Check and Act
4. Kanban is based on a model of?
A. Shipyards B. Automotive assembly lines C. Supermarkets D. Software
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Answer Explanation -1 and 2
Answer 1: The right answer in this case is C. The five steps in 5S are Sort, Set-in-Order, Shine, Standardize, and Sustain. Answer 2: The right answer in this case is B. Work area personnel record the date of an item's last use on these tags, along with other information used to justify removal. Red tags are first used, as needed, in sort to identify items for removal, in all subsequent steps during and after implementation. Answer 3: The right answer in this case is B. PDCA stands for Plan, Do, Check, Act. Answer 4: The right answer in this case is C. Taiichi Ohno was inspired by the American supermarket’s working and applied to auto industry.
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