Introductions • Name • Company • Current position • Years of service
Workshop Techniques Utilize “Lean Organization” approaches focused on aggressively identifying and eliminating waste. Driving Enhanced Service Technology Quality Price Which results in • Increased Capability to Deliver Great Products/Services • Greater Value for the Customer • Improved Worldwide Competitiveness
Q S T P Goal • Transfer knowledge / commitment to lean • Redefine / improve an existing process • Involve team members • Aggressively implement the changes • Identify future process improvements • Demonstrate the magnitude of improvement potential
Expectations • Safety cannot and will not be compromised! • The team will aggressively identify & eliminate WASTE • Significant improvement will be gained in the measurement parameters
Select team members Define current situation Identify pilot area Discuss plan with stakeholders OPERATION: FROM:___________________________ QUANTITY PER SHIFT:______________ CUSTOMER CYCLE TIME:__________________ TO: _____________________________ SHIFT:________ OPERATOR CYCLE TIME:__________________ STANDARD IN- QUALITY DESCRIPTION OF ELEMENT TIME CRITICAL Q C SAFETY PROCESS STOCK OPERATION NO. OPERATION HAND WORK MACHINE WALK CHECK WORKSTATION AREA DRAWN TO SCALE 03/23/94 Make all people affected aware of what is going to happen Process Identify opportunities to improve Look for new opportunities Recognize efforts of people Analyze &select Verify & adjust Develop new method (apply zero/low cost ideas first) Implement new method A.S.A.P.
Defining Lean • Occurring at the same time • To be simultaneous • To operate in unison • To coincide with an action • Moving at the same rate • Minimum use of resources
Lean Organization Definition: A systematic approach to the identification and elimination of waste and non-value added activities through continuous improvement in all products and services
Lean Organization • Characteristics: • Equipment used synchronously to demand • Utilizes people to their fullest capacity • Simple, flexible, visible, & responsive • Requires constant change • Creates products/services with minimum consumption of: • - Capital investment • - Floor space • - Materials • - Labor • - Time • - Distance
Lean Organization Pull Systems Small Lots Standardized Operations Machine Process Capability Level Scheduling Supplier Development Reduction of Variation Lean Organization Lead Time Reduction Transportation Plant, Machine & Office Layout Error Proofing Containerization Workplace Organization & Visual Controls Planned Maintenance Quick Set-up Employee / Process Control 09/23/97
Workshop Path to Lean Organization Step #1 Step #2 Waste Elimination Tools What is Waste? Lean Organization Step #4 Step #3 Brainstorming & Visioning Aggressive Implementation 01/20/98
Lean Organization Our Four Step Focus • Step One - Understand what waste is • Step Two - Use appropriate waste elimination tool • to eliminate specific waste(s) identified • Step Three - Brainstorm to develop a vision so as • to create a plan • Step Four - Aggressive implementation of plans. • Do it now!!!! 01/20/98
Lean Implementation Training Agenda Example DAY 1: 8:00 - 5 00 DAY 2: 8:00 - ? DAY 3: 8:00 - ? DAY 4: 8:00 - 12:00 • Introductions • Why we are here: • Competitive situation • Market conditions • Define Concepts • Waste • Lead Time • Value Added • Non Value Added • Standardized Operations • Workplace Organization • Visual Controls • Define Current State • Productivity • Inventory • Layout • Lead Time Brainstorm potential solutions to opportunities Develop new working method Discuss plan with stakeholders Analyze, select, prioritize good ideas Implement new working method • Continue Implementation • Finalize Implementation • Verify • Adjust Document improved and future states Prepare wrap-up presentation Give wrap-up presentation
Date of Workshop: ____________ Short Term F/U date: ____________ Long Term F/U date: ____________ Lean Implementation WorkshopSummary of Results Supplier: Sponsoring Division: Process: PPAP Requirements Addressed (Y/N) Creativity Team Name & Number: After Workshop Before Workshop Parameters Short Term (0-6 months) Long Term (6-12 months) Improved State (Current Week) Measure %Improved Measure %Improved Measure %Improved Productivity (parts/person/day) Forecast Actual Forecast Inventory ($) Actual Forecast Layout (Feet) Actual Forecast Lead Time (Time______) Actual Additional Savings Identified Subject # of Items Date & updated $ Potential $ Approved $ Rejected Resource Conservation & Pollution Prevention Other: Investment, Specifications, Transportation, etc. TOTAL: Team Leader Name/Phone:
Norms(Operating Guidelines) 1. Be on time 2. Everyone participates, has equal voice 3. One speaker at a time 4. Handle other business on breaks 5. Make pagers silent 6. Function as a team 7. Speak loudly and clearly 8. No one leaves until the new process works! 9. HAVE FUN!
Administrative Details • Classroom location(s) • Rest room(s) • Telephones • Message handling / contact phone number • Lunch area / timing • Refreshments • Copy machines • Safety requirements • Starting / ending time