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Lean Six Sigma Methodology http://www.tefen.com/industries.asp?pageInstanceId=150 Attributes of Lean Producers - they use JIT to eliminate virtually all inventory build systems to help employees produce a perfect part every time reduce space requirements

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Lean Six Sigma Methodology

http://www.tefen.com/industries.asp?pageInstanceId=150


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Attributes of Lean Producers - they

  • use JIT to eliminate virtually all inventory

  • build systems to help employees produce a perfect part every time

  • reduce space requirements

  • develop close relationships with suppliers

  • educate suppliers

  • eliminate all but value-added activities

  • develop the workforce

  • make jobs more challenging

  • reduce the number of job classes and build worker flexibility


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Waste in Operations

  • Overproduction

  • Waiting time

  • Transporting

  • Non-value added processing

  • Inventory

  • Defects

  • Underutilized talent

Fig. 15.1, p. 686


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Time Function Map

Receive product

Order Product

Customer

Process Order

Sales

Productioncontrol

Order

Wait

Order

Print

Plant A

Product

WIP

Wait

Wait

Wait

Warehouse

Product

WIP

Plant B

Extrude

Product

WIP

WIP

Transport

Move

Move

12 days

13 days

1 day

4 days

1 day

10 days

9 days

1 day

1 day


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Production Process Flow Diagram

Customer

Purchasing

(order inks, paper, other supplies)

Customer sales representative

take order

Vendors

Prepress Department

(Prepare printing plates and negatives)

Receiving

Accounting

Printing Department

Warehousing

(ink, paper, etc.)

Gluing, binding, stapling, labeling

Collating Department

Information flow

Material flow

Polywrap Department

Shipping


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5 WhysExample

The Washington Monument is disintegrating.Why? Use of harsh chemicalsWhy? To clean pigeon poopWhy so many pigeons? They eat spiders and there are a lot of spiders at monumentWhy so many spiders? They eat gnats and lots of gnats at monumentWhy so many gnats? They are attracted to the light at dusk.Solution: Turn on the lights at a later time.


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5 S Philosophy

  • Seiri – Sort

  • Seiton – Set in Order

  • Seiso – Shine

  • Seiketsu – Standardize

  • Shitsuke – Sustain


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90 min

Initial Setup Time

Separate setup into preparation, and actual setup, doing as much as possible while the machine/process is running (save 30 minutes)

Step 1

60 min

Move material closer and improve material handling (save 20 minutes)

Step 2

45 min

Standardize and improve tooling (save 15 minutes)

Step 3

25 min

Use one-touch system to eliminate adjustments (save 10 minutes)

Training operators and standardizing work procedures (save 2 minutes)

Step 4

Step 4

15 min

13 min

Step 5

Steps to Reduce Setup Time


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Small versus Large Lots

JIT produces same amount in same time if setup times are lowered

JIT Small Lots

C

A

A

B

B

B

C

A

A

B

B

B

Time

Small lots also increase flexibility to meet customer demands

Large-Lot Approach

C

A

A

A

A

B

B

B

B

B

B

C


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JIT Reduced Wasteat Hewlett-Packard

Waste Reduction (%)

Setup Time

20%

Scrap

30%

Finished Goods Inventory

30%

Space

40%

Lead Time

50%

Raw Material Inventory

50%

Work-in-Process Inventory

82%

0%

20%

40%

60%

80%

100%


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Visible Kanban (Control)

Production

Move

Production

Move

1- Card Kanban

2-Card Kanban

Visible Kanban


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JIT Experiential Exercise


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Kaizen – Continuous Improvement

DMAIC

Define

Measure

Analyze

Improve

Control


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Kaizen – Continuous Improvement

PDSA

Plan

Do

Study

Act


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