NEXT GENERATION OF LEAN MANUFACTURING Principles of Lean

NEXT GENERATION OF LEAN MANUFACTURING Culture Products People History of Manufacturing Pre-industrial 1890 Mass

NEXT GENERATION OF LEAN MANUFACTURING Traditional Mass Production Material Casting Machining Plating Receiving Warehouse

NEXT GENERATION OF LEAN MANUFACTURING Cycle and Lead Time “One of the most noteworthy

NEXT GENERATION OF LEAN MANUFACTURING Defining Lean “A systematic approach to identifying and eliminating

NEXT GENERATION OF LEAN MANUFACTURING Definition of Value-added ¿ Value-added Any activity that increases

NEXT GENERATION OF LEAN MANUFACTURING What Is Waste? Waste is “anything other than the

NEXT GENERATION OF LEAN MANUFACTURING Lean = Eliminating the Wastes Overproduction of work in

NEXT GENERATION OF LEAN MANUFACTURING Examples of the Eight Wastes Watching a machine run—underutilized

NEXT GENERATION OF LEAN MANUFACTURING Why Focus on the Eight Wastes? ¿ The eight

NEXT GENERATION OF LEAN MANUFACTURING Lean Building Blocks © Time Wise Solutions, LLC. All

NEXT GENERATION OF LEAN MANUFACTURING Elements of 5 S: Creates the Stability for Systematic

NEXT GENERATION OF LEAN MANUFACTURING Elements of 5 S Sort – Eliminate the clutter

NEXT GENERATION OF LEAN MANUFACTURING Why Have Workplace Organization? A workplace that is clean,

NEXT GENERATION OF LEAN MANUFACTURING Sort: Change-over Cart Dirty Clutter Cart in poor condition

Set in Order / Set Limits Change-over Cart NEXT GENERATION OF LEAN MANUFACTURING Only

NEXT GENERATION OF LEAN MANUFACTURING Elements of 5 S © Time Wise Solutions, LLC.

NEXT GENERATION OF LEAN MANUFACTURING Shine: Before cleaning & painting Why is there quick

NEXT GENERATION OF LEAN MANUFACTURING Shine: After cleaning & painting Safety yellow for guards

NEXT GENERATION OF LEAN MANUFACTURING Standardize: Visual Storage Material and quantity managed at a

NEXT GENERATION OF LEAN MANUFACTURING Standardize: Standards do not need to be documents Scrap

NEXT GENERATION OF LEAN MANUFACTURING Standardize: Posted 5 S standards with ownership; Worker managed

NEXT GENERATION OF LEAN MANUFACTURING Sustain: Allow the Team to set the standards they

NEXT GENERATION OF LEAN MANUFACTURING Sustain: Posted, visual instructions & Check lists © Time

NEXT GENERATION OF LEAN MANUFACTURING Visual Controls: Management by Sight © Time Wise Solutions,

NEXT GENERATION OF LEAN MANUFACTURING Visual Controls Simple visual signals give the operator the

NEXT GENERATION OF LEAN MANUFACTURING Why Make It Visual? ¿ ¿ Easily understood Supports

NEXT GENERATION OF LEAN MANUFACTURING Visual Controls © Time Wise Solutions, LLC. All Rights

NEXT GENERATION OF LEAN MANUFACTURING Videos on 5 S (Good summary) ¿ ¿ ¿

Slides: 33

Download presentation

NEXT GENERATION OF LEAN MANUFACTURING Culture Products People History of Manufacturing Pre-industrial 1890 Mass Production 1920 Lean 1980 Craftsmen Production Teams Highly Skilled, Self-taught, Apprenticed from Master Limited Skills, Repetition, Mind Numbing Work Diverse Skills, Continuous Training Customized Standardized Variety “One of a Kind, ” Variable Quality High Volume, Low Variety, Manufacturer Focused Lower Volume, High Variety, Customer Focused Independent Dependent Empowered Entrepreneurs, Responsible, Managers Think, Workers Do, Small Business Labor vs. Management Shared Accountability and Responsibility, Group Effectiveness The Lean Enterprise Is Market Driven! © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Traditional Mass Production Material Casting Machining Plating Receiving Warehouse Storage Shipping Warehouse Rework Inspection Kitting Ship ORDER © Time Wise Solutions, LLC. All Rights Reserved. Value-added Time: Time in Plant: Minutes Weeks CASH

NEXT GENERATION OF LEAN MANUFACTURING Cycle and Lead Time “One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost. ” —Henry Ford, 1926 © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Defining Lean “A systematic approach to identifying and eliminating waste (non value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. ” —The MEP Lean Network © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Definition of Value-added ¿ Value-added Any activity that increases the market form or function of the product or service. These are activities the customer is willing to pay for. ¿ Non Value-added Any activity that does not add market form or function or is not necessary. These activities should be eliminated, simplified, reduced, or integrated. © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING What Is Waste? Waste is “anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are absolutely essential to add value to the product. ” —Shoichiro Toyoda President, Toyota © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Lean = Eliminating the Wastes Overproduction of work in process ¿ Waiting ¿ Transportation of parts/materials/tooling 5% ¿ Non Value-added processing Value-added ¿ Excess finished inventory ¿ Defects 95% ¿ Excess people motion Nonvalue-added ¿ Underutilized people ¿ Typically, 95% of all lead time is nonvalue-added © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Examples of the Eight Wastes Watching a machine run—underutilized people ¿ Waiting for parts—waiting ¿ Counting parts—non value-added processing ¿ Making more than can be sold—excess inventory ¿ Moving parts over long distances—transportation ¿ Storing Work In Process Inventory—overproduction ¿ Looking for tools—excess motion ¿ Machine breakdown—waiting, defects ¿ Rework—defects, non value-added processing ¿ Redundant inspections—non value-added processing ¿ © Russell and Taylor, Operations Management, 2 nd ed. Prentice-Hall, Inc. , 1998. © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Why Focus on the Eight Wastes? ¿ The eight wastes are symptoms ¿ Recognizing waste leads to identifying the root cause of problems ¿ Underlying any waste is a systemic flaw involving people, materials, machines, and/or information © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Elements of 5 S Sort – Eliminate the clutter “When in Doubt, Throw It Out!” Set in Order – Organize and label, set boundaries and limits “A Place for Everything and Everything in Its Place” Shine – Clean everything, inside and out “Inspection Through Cleaning” Standardize – Keep maintenance checklists; make them visual “Everything in a State of Readiness” Sustain – Maintain discipline through systems and a supportive culture © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Why Have Workplace Organization? A workplace that is clean, organized, orderly, safe, efficient, and pleasant results in: ¿ Fewer accidents ¿ Improved efficiency ¿ Reduced searching time ¿ Reduced contamination ¿ Visual workplace control ¿ A foundation for all other improvement activities © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Visual Controls Simple visual signals give the operator the information to make the right decision. They are efficient, self-regulating, and worker-managed. Examples: ¿ Kanban ¿ Color-coded dies, tools, pallets ¿ Lines on the floor to delineate storage areas, walkways, work areas, etc. ¿ Andon lights © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Why Make It Visual? ¿ ¿ Easily understood Supports a diverse workforce Supports workplace safety Allows immediate assessment of conditions by workers, team leaders, and managers “Let the shop floor speak to you!” —Dr. Gwen Galsworth © Time Wise Solutions, LLC. All Rights Reserved.

NEXT GENERATION OF LEAN MANUFACTURING Videos on 5 S (Good summary) ¿ ¿ ¿ https: //www. youtube. com/watch? v=H 63 ZKS 5 q DDY (1’ 38”) https: //www. youtube. com/watch? v=FZm. BQR m. Dg. Ic (3’ 36”) https: //www. youtube. com/watch? v=NJNlsk_DLU (2’ 11”) © Time Wise Solutions, LLC. All Rights Reserved.