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

Lean Manufacturing Lean Six Sigma Total Quality Management Agile Manufacturing Toyota Production System Six Sigma Theory of Constraints

Eliminate Waste Increase Speed & Response Improve Quality Reduce Cost

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

Transportation Inventory Motion Waiting Over-production Over-processing Defects T I M W O D

5S Visual Controls SMED Small Batch Single Piece Flow Quality and Continuous Improvement Total Productive Maintenance Manufactured Good Recovery

 Sort - Seiri (Organization)  Set In Order – Seiton (Orderliness)  Shine – Seiso (Cleanliness)  Standardize – seiketsu (Standardized Cleanup)  Sustain - Shitsuke (Discipline)

5 Pillars of the Visual Workplace, Hirano, p. 20, 1995

(Single Minute Exchange of Die) 1. Pre – changeover 2. During changeover 3. Startup 4. After Startup Increases capacity by creating more available production time.

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

Advanced Statistical Methods (TQM, Six Sigma) W. Edwards Deming, Motorola Zero Quality Control – Quality at the source (Poka Yoke) Shingeo Shingo

Define Measure Analyze Improve Control Design of Experimentation (DOE)

 Business Process Kiazen (Value Stream)  Kiazen Workshops (5S Event)  Daily Kiazen (Daily Improvement)

 Participation of all employees (not just maintenance)  Identify problems before they are problems  Correct problems when down time can be planned  Decreases production variablilty

Pull vs. Push Inventory Management (Supermarket – Kanban) Production Management (Level loading – Heijunka)

 Managing waste streams  Recycling