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Lean Manufacturing. Lean Industries Series. Outline. Lean Manufacturing 5S & Visual Controls Kaizen Value Streams Pull Manufacturing Mistake Proofing Quick Changeover Six Sigma Lean Accounting Theory of Constraints Human Factors. What is Lean?.

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lean manufacturing

Lean Manufacturing

Lean Industries Series

outline
Outline
  • Lean Manufacturing
  • 5S & Visual Controls
  • Kaizen
  • Value Streams
  • Pull Manufacturing
  • Mistake Proofing
  • Quick Changeover
  • Six Sigma
  • Lean Accounting
  • Theory of Constraints
  • Human Factors
what is lean
What is Lean?
  • Lean production focuses on eliminating waste in processes (i.e. the waste of work in progress and finished good inventories)
  • Lean production is not about eliminating people
  • Lean production is about expanding capacity by reducing costs and shortening cycle times between order and ship date
  • Lean is about understanding what is important to the customer
identify the customer
Identify the Customer
  • Value added is always determined from the customer’s perspective.
  • Who is the customer?
  • Every process should be focused on adding value to the customer.
  • Anything that does not add value is waste.
  • Some non-valued added activity is necessary waste (“NVA-R”)
    • Regulatory
    • Legal
roadblocks
Roadblocks
  • Too busy to study it
  • A good idea but the timing is premature
  • Not in the budget
  • Theory is different from practice
  • Isn’t there something else for you to do?
  • Doesn’t match corporate policy
  • Not our business – let someone else analyze it
  • It’s not improvement – it’s common sense
  • I know the result even if we don’t do it
  • Fear of accountability
  • Isn’t there an even better way?
kanban squares

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Kanban Squares

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Flow of work

Flow of information

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