Lean Tools & Approaches

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Presentation transcript:

Lean Tools & Approaches Lean Six Sigma Training Satish Nargundkar

Waste (“Muda”) Elimination Types of Waste – TIM WOOD T ransportation I nventory M ovement W aiting O verproduction O ver-processing D efects Spaghetti Diagram (Source: http://leanprogression.co.uk/lean-techniques/spaghetti-diagram) Youtube Video

Smooth Flow: Takt Time, Cycle Time, Throughput Time German “Takt” means Beat, as in the timing of music. It sets the rate at which the process should operate based on customer demand. Takt Time = Time Available/Customer Demand Cycle Time Time interval between finished goods (between one piece exiting the system and the next) Cycle time also can refer to the time taken to complete each step in the process. Throughput Time: Time for one part to move through system. Six Sigma Academy Amsterdam Video

Value Stream Mapping (VSM) Goal: To understand what is actually happening in the process. To help see problems clearly. Drawing the VSM Show process steps Note time taken for each step (Value Added Time) Note time between steps (Non Value Added Time) Sum both for the entire process Compute efficiency GEMBA: Walk the process! Take samples, note variations too. Ron Pereira, GEMBA Academy Blog

VSM Exercise Draw a value stream map Process: Laundry (one washer, one dryer) Four people waiting to start washing. Loading takes 3 minutes Washer takes 40 minutes. Transfer to dryer takes 3 minutes 6 loads waiting to dry Dryer takes 80 minutes Folding/hanging takes 10 minutes What is the Cycle Time? Throughput Time?

Kaizen One week process to implement Lean Source: http://jipsportsbj.info/kaizen-presentation-format/kaizen-presentation-format-0714-kaizen-event-process-powerpoint-presentation-slide-template-download/