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What is Lean?. Lean is a business system that focuses on doing only those things that add value to the customer, creating continuous one piece flow, and placing a high value on developing people at all levels of the organization.

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What is lean
What is Lean?

Lean is a business system that focuses on doing only those things that add value to the customer, creating continuous one piece flow, and placing a high value on developing people at all levels of the organization.

Brian Hatcher


Improvement methods
Improvement Methods

Lean Manufacturing

Lean Six Sigma

Total Quality Management

Agile Manufacturing

Toyota Production System

Six Sigma

Theory of Constraints


Principles of a lean operating system

Principles of a Lean Operating System

Eliminate Waste

Increase Speed & Response

Improve Quality

Reduce Cost


Waste muda
Waste - Muda

Waste is anything that the customer is not willing to pay for.

Necessary Waste - Customer does not want to pay for but is willing to pay for – does not add value to the product

Un-necessary Waste – Does not transform the product – we want to get rid of this waste


7 wastes in an organization
7 Wastes in an Organization

Transportation

Inventory

Motion

Waiting

Over-production

Over-processing

Defects

T

I

M

W

O

O

D


Lean tools

Lean Tools

5S

Visual Controls

SMED

Small Batch Single Piece Flow

Quality and Continuous Improvement

Total Productive Maintenance

Manufactured Good Recovery



5 S

  • Sort - Seiri (Organization)

  • Set In Order – Seiton (Orderliness)

  • Shine – Seiso (Cleanliness)

  • Standardize – seiketsu (Standardized Cleanup)

  • Sustain - Shitsuke (Discipline)




Smed quick change
SMED – Quick Change

(Single Minute Exchange of Die)

  • Pre – changeover

  • During changeover

  • Startup

  • After Startup

    Increases capacity by

    creating more available

    production time.


Single piece flow
Single Piece Flow

Make small batches and changeover quickly or single piece flow from pone process to the next.

Value Stream Thinking

( From dirt to shelf )

Takt Time =

available production time per day

customer demand per day

This is the customer demand for your product or service… the pace at which you must produce.


Value Stream Mapping Workshop, Rother and Shook, p. 71, 2002


Value Stream Mapping Workshop, Rother and Shook, p. 72, 2002


Quality
Quality

Advanced Statistical Methods

(TQM, Six Sigma)

W. Edwards Deming, Motorola

Zero Quality Control – Quality at the source

(Poka Yoke)

Shingeo Shingo


Lean six sigma
Lean Six Sigma

Define

Measure

Analyze

Improve

Control

Design of Experimentation (DOE)


Kiazen continuous improvement
Kiazen(Continuous Improvement)

  • Business Process Kiazen (Value Stream)

  • Kiazen Workshops (5S Event)

  • Daily Kiazen (Daily Improvement)


The deming shewhart cycle
The Deming (Shewhart) Cycle


Tpm total productive maintenance
TPM (Total Productive Maintenance)

  • Participation of all employees (not just maintenance)

  • Identify problems before they are problems

  • Correct problems when down time can be planned

  • Decreases production variablilty


Just in time systems

Just in Time Systems

Pull vs. Push

Inventory Management

(Supermarket – Kanban)

Production Management

(Level loading – Heijunka)


Manufactured good recovery
Manufactured Good Recovery

  • Managing waste streams

  • Recycling



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