Road Map for Implementing Lean Manufacturing

1 → Identify a product family (with similar routings) to start with and an area to begin in, usually at or near final assembly2 → Determine daily demand rate for each item3 → Identify processes for common items to be included in lean cell/line4 → Calculate takt times for each process5 → Define the standard work content6 → Calculate amount of resources for each process7 → Determine cell/flow line general layout8 → Balance the Work Flows9 → Calculate the number of kanban containers (the amount of WIP)10 → Follow the Steps for Implementing a Lean Project (Implementation Level 3)11 → Begin to use pull signals to draw material from the feeder operations and outside suppliers, but continue to use inventory as a buffer until they can respond to the pull signals 12 → Develop Lean capabilities, following the Steps for Implementing a Lean Project, for the next upstream feeder operation 13 → Follow step 11 for this feeder operation 14 → Repeat steps 12 and 13, cascading up the supply chain, for the next upstream operation, and for the key suppliers