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lean

lean. What is Lean?. Lean is a systematic approach to reduce or eliminate activities that don't add value to the process. It emphasizes removing wasteful steps in a process and taking the only value added steps. It helps in. reducing process cycle time,

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lean

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  1. lean

  2. What is Lean? • Lean is a systematic approach to reduce or eliminate activities that don't add value to the process. It emphasizes removing wasteful steps in a process and taking the only value added steps.

  3. It helps in • reducing process cycle time, • improving product or service delivery time, • reducing or eliminating the chance of defect generation, • reducing the inventory levels and • optimizing resources for key improvements among others.

  4. What is “Value”? • “Value” is related to customer’s perception of product(s) or service(s), which he or she is willing to pay for. 

  5. 3 Types Activities • Non- Value-added activity: These activities do not add any value to the processor products. They form the wasteful steps. A customer doesn’t pay for the costs associated with these activities willingly.  Rather, if present excessively they result in customer dissatisfaction. • Value-added activity: These activities add value to the process and are essential. They improve processes for productivity and quality. • Enabling value-added activity: These activities do not add value to a customer. They are necessary for continuity of a process. Notes: • Almost 80 – 85% activities are non-value adding activities. • The aim of LEAN approach is to identify them in the process. And use specific lean tools to eliminate or reduce them. Thus, Lean improves process efficiency.

  6. Removing Waste • Using the Lean methodology, you can remove below mentioned eight types of waste.

  7. some important Lean tools: • VSM (Value stream mapping): As already discussed, VSM helps to identify process wastes and causes of these wastes. • Kaizen: It’s a continuous improvement approach focusing on small – small improvements. It involves the commitment of down level people in the organization towards process improvements, facilitated by subordinates and supported by management.  • Just in Time: It’s a pull approach to meet customer demands as & when it flows from a customer. • SMED (Single minute exchange of dies): It improves equipment changeover time. It works on a principle of reducing changeover time to within ten minutes. • Poke Yoke: It’s a mistake-proofing device used in assembly to alert operators on defects or failures. • Jidoka (Autonomation): Also known as intelligent automation. It stops the assembly or production line if a defect occurs. • Heijunka: It’s the concept of Line Balancing. The aim is to evenly distribute the load by balancing production lines. • Gemba (Go & See): The aim is to go to the actual place of work. Observe the process and executions in real time with care. Record the observations. It’s another way to find process pitfalls. • Kanban: It’s a signal system to manage inventory level. Kanban boards can be displayed and managed to see the current inventory level on a real time basis. It also alerts to the management to bring the attention over excessive inventory. Excessive inventory ties up the working capital and blocks it from productive usage.

  8. What is Six Sigma? • Six Sigma is a data-driven problem-solving methodology. 

  9. The goal of Six Sigma:  • The aim of  Six Sigma is to make a process effective with - 99.99996 % defect free. This means a six sigma process produces in 3.4 defects per million opportunities or less as a result.

  10. Six Sigma Phase

  11. What is Lean Six Sigma? “Lean Six Sigma is a fact-based, data-driven philosophy of improvement that values defect prevention over defect detection. 

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