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Effective Lean Implementation Techniques to Achieve Bottom Line Results. Presented By Baskar Kotte Quality Systems Enhancement, Inc. 1790 Woodstock Road Roswell, Georgia 30075 Toll Free : 1-866-577-4476 [email protected] www.enhancequality.com. Lean: The QSE Focus. Lean.

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effective lean implementation techniques to achieve bottom line results

Effective Lean Implementation Techniques to Achieve Bottom Line Results

Presented By Baskar Kotte

Quality Systems Enhancement, Inc.

1790 Woodstock Road

Roswell, Georgia 30075

Toll Free : 1-866-577-4476

[email protected]

www.enhancequality.com

lean the qse focus
Lean: The QSE Focus

Roswell, Georgia [email protected] 1-866-577-4476

slide3
Lean
  • Not just lean manufacturing
  • Lean is an enterprise
  • Lean enterprise covers all areas of business

Roswell, Georgia [email protected] 1-866-577-4476

lean enterprise focus
Lean Enterprise Focus
  • Achieve more with less
  • Minimize inventory at all stages of production
  • Improve machine efficiency and delivery performance
  • Eliminate waste of all kinds (time-material)
  • Error-proof process with problem solving techniques
  • Reduce purchasing cost and customer credits
  • Improve information system
  • Improve quality and customer satisfaction

Roswell, Georgia [email protected] 1-866-577-4476

slide5

Definition of Lean Enterprise

  • Lean enterprise is a balanced organization

Discipline

Problem solving

Empowered

Employees

ISO

Roswell, Georgia [email protected] 1-866-577-4476

slide6

Definition of Lean Enterprise

  • Causes of failure

Not my job

I am the Boss

No discipline

No problem

solving

No commitment

Roswell, Georgia [email protected] 1-866-577-4476

lean tool mumbo jumbo
Lean Tool Mumbo Jumbo
  • Production leveling / smoothing
  • Point-of-use systems
  • Kanban
  • Kaizen
  • Single Minute Exchange of Dies (SMED)
  • Standardized work
  • Statistical Problem Solving (SPS)
  • Balanced Scorecard
  • Value stream mapping
  • Quality at the source
  • Workplace organization: 6S
  • Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE)
  • Visual management
  • Batch size reduction
  • Cellular manufacturing
  • Work balancing (TAKT-time)

Roswell, Georgia [email protected] 1-866-577-4476

lean tools for the box industry
Lean Tools for the Box Industry
  • Value stream mapping
  • 6S
  • Visual management
  • Statistical Problem Solving (SPS) techniques
  • Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE)
  • Work balancing (TAKT-time)
  • Kanban
  • Kaizen
  • Single Minute Exchange of Dies (SMED)

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques value stream mapping
Understanding Selected Tools and Techniques: Value StreamMapping

How long does it take for value stream mapping?

  • 6 weeks?
  • 4 weeks?
  • 1 week?

If it takes more than 4 hours, then we are wasting our time

Roswell, Georgia [email protected] 1-866-577-4476

slide10

Quote

Quote to Cash

Value stream

map

  • Understanding the process
  • steps
  • Picking the process which has
  • more $$ value impact
  • Picking right tools

Cash

This flow diagram required for ISO as well

Roswell, Georgia [email protected] 1-866-577-4476

10

understanding selected tools and techniques oee
Understanding Selected Tools and Techniques: OEE

Overall Equipment Effectiveness =

Availability % x Performance %

x Quality% x 100

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques oee12
Understanding Selected Tools and Techniques: OEE

Understanding Selected Tools and Techniques: OEE

Production Time – Down Time

Available Time

480 mins. – 60 mins

480

A=

X 100 = 87%

X 100 =

# of Boxes Produced

Actual Machine Run Capability %

8,000

10,000

P=

X 100 = 80%

X 100 =

Good Boxes

Total # of Boxes Run

98,000

100,000

Q=

X 100 = 98%

X 100 =

A= availability

P= performance

Q= quality

OEE= A x P x Q x 100

.87 x .80 x .98 x 100 = 68.2 %

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques takt time
Understanding Selected Tools and Techniques: TAKT Time

TAKT time is the rate at which customers require the product

TAKT time is computed as:

Available work time per day(480-BREAKS)

Daily required customer demand in BOXES per day

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques visual management
Understanding Selected Tools and Techniques: Visual Management
  • Charts
  • Metrics
  • Procedures
  • Process documentation

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques quick setups
Understanding Selected Tools and Techniques: Quick Setups
  • SMED
  • Effective implementation of 6S
  • Machine center lining, zero gear trains, time and register
  • Standardization of cutting dies and printing plates

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques kanban
Understanding Selected Tools and Techniques: Kanban
  • A pull material replenishment system, based on the principle that material is pulled through the production process based on actual usage of material
  • Kanban uses visual signals, usually a card, to move material through the value chain

Roswell, Georgia [email protected] 1-866-577-4476

understanding selected tools and techniques kaizen
Understanding Selected Tools and Techniques: Kaizen
  • Continuous improvement through incremental improvement
  • The whole secret to Kaizen is to create an atmosphere, a culture of continuous improvement, by focusing on problems not on people .
  • Kaizen compliments the other tools of Lean and it is part of a whole rather than a stand-alone process

Roswell, Georgia [email protected] 1-866-577-4476

lean tools and techniques statistical problem solving
Lean Tools and Techniques:Statistical Problem Solving

The steps of Statistical Problem Solving

  • Defining the problem
  • Listing suspected variables
  • Prioritizing variables using subjective rating
  • Evaluating the critical few variables by conducting studies and trials
  • Optimizing variable settings

Roswell, Georgia [email protected] 1-866-577-4476

qse s approach to cost reduction
QSE’s Approach to Cost Reduction
  • Quotation to cash
  • Follow the money
  • Application of disciplined problem solving
  • Top 5 $$$ impacting items

Roswell, Georgia [email protected] 1-866-577-4476

example problems picked by our customers maximum impacting bottom line
Example Problems Picked By Our Customers – Maximum $$$ Impacting Bottom Line
  • Excessive inventory (wip, ink, sheets, finished goods)
  • Purchasing (cost of raw materials, uncontrolled

purchasing methods)

  • Set up time reduction
  • Over runs
  • Supplier sheets (defects)
  • Estimation, quotes time
  • Incomplete information on RFQs
  • Incorrect customer specs
  • Maintenance parts inventory (old obsolete, doubled up parts)
  • Ineffective or non-existing procedures and instructions

Roswell, Georgia [email protected] 1-866-577-4476

qse s proven lean implementation guidance
QSE’s Proven Lean Implementation Guidance
  • Recognize lean as a long term journey
  • Recognize obstacles to change
  • Adequate resource allocation
  • Focus on both manufacturing and non manufacturing areas

Roswell, Georgia [email protected] 1-866-577-4476

qse s proven lean implementation guidance22
QSE’s Proven Lean Implementation Guidance
  • Benchmark but do not copy
  • One system
  • Synchronize lean goals with business goals
  • Empowerment / team approach
  • Create an atmosphere, a culture of continual improvement

Roswell, Georgia [email protected] 1-866-577-4476

defined path for effective lean implementation
Defined Path for Effective Lean Implementation

1.Lean Tools and concepts training

2. Baseline assessment/establishment of goals and metrics

3. Selection of appropriate lean tools and concepts

Roswell, Georgia [email protected] 1-866-577-4476

defined path for effective lean implementation24
Defined Path for Effective Lean Implementation

4. Train the implementation team for the application of the selected tools and concepts

5. Assist in the application of the selected tools and concepts

Roswell, Georgia [email protected] 1-866-577-4476

defined path for effective lean implementation25
Defined Path for Effective Lean Implementation

6. Monitor and audit improvement against goals, re-evaluate the process if necessary

7. Fine-tuning of the processes to achieve value-added results

Roswell, Georgia [email protected] 1-866-577-4476

defined path for effective lean implementation26
Defined Path for Effective Lean Implementation

8. Maximize/optimize implementation effectiveness for bottom line improvement

9. Incorporate results into standardized procedures

10. Management review of accomplished results

Roswell, Georgia [email protected] 1-866-577-4476

effective lean implementation qse difference
Effective Lean Implementation: QSE Difference
  • Not just promise – GUARANTEED 15% waste reduction from baseline assessment
  • Not just train – ASSIST in implementation
  • Not just manufacturing – ALL non manufacturing areas of the business

Roswell, Georgia [email protected] 1-866-577-4476

effective lean implementation qse difference28
Effective Lean Implementation: QSE Difference

Not just problem identification – ASSIST in systematic problem solving

Not just team building – TRAIN the team in problem solving techniques

Roswell, Georgia [email protected] 1-866-577-4476

effective lean implementation qse difference29
Effective Lean Implementation: QSE Difference
  • Not just lean, COMBINE ISO, lean and problem solving to sustain bottom line results
  • Integrate all lean procedures and instructions into one manageable simplified ISO process approach
  • Audit lean results for sustainability integrated with ISO auditing techniques

Roswell, Georgia [email protected] 1-866-577-4476

successful lean implementation
Successful Lean Implementation
  • No lean strategy will work until process is error proofed with:
  • Disciplined/defined path
  • Problem solving techniques
  • Simplistic ISO (if applicable)

Roswell, Georgia [email protected] 1-866-577-4476

successful lean implementation integrate with iso
Successful Lean Implementation: Integrate with ISO
  • One level documentation
  • Realistic
  • Practical
  • Internal auditing for continual improvement
  • Control of nonconformities
  • Corrective and Preventive action plans

Roswell, Georgia [email protected] 1-866-577-4476

successful lean implementation problem solving
Successful Lean Implementation: Problem Solving
  • Systematic/Statistical Problem Solving
  • Effective root cause analysis
  • Apply sustainable, permanent problem solving techniques
  • Problem solving is a problem

Roswell, Georgia [email protected] 1-866-577-4476

effective lean implementation summary
Effective Lean Implementation Summary
  • Lean Focus
  • Definition of Lean Enterprise
  • Lean Tool Selection
  • Understanding Selected Tools/Techniques
  • QSE’s Approach to Cost Reduction

Roswell, Georgia [email protected] 1-866-577-4476

effective lean implementation summary34
Effective Lean Implementation Summary
  • QSE’s Proven Lean Implementation Guidance
  • Defined Path for Effective Lean Implementation
  • Effective Lean Implementation: QSE Difference
  • Successful Lean Implementation: Integrate with ISO

Roswell, Georgia [email protected] 1-866-577-4476

effective lean enterprise summary
Effective Lean Enterprise Summary
  • Successful Lean Implementation: Problem Solving
  • Successful Lean Enterprise has commitment and involvement at all levels of the organization

Roswell, Georgia [email protected] 1-866-577-4476

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