Review of Lean Topics Dewey Warden

Lean Basics Value stream mapping The seven wastes 5S’s Processes and operations Process flow and cell design Process standardization Overview of quick changeovers

Value Stream Mapping It is the simple process of directly observing the flows of information and materials as they occur, summarizing them visually, and then envisioning a future state with a much better performance.

Value Stream Mapping Levels of mapping Process Single plant Multiple plant Across companies

Value Stream Mapping Creating the value stream maps Walk along the value stream Look for Which steps create value? Which steps are waste? Why is order flow so erratic? Why is quality so erratic? How can value be enhanced for the end-customer?

Value Stream Mapping Creating the value stream maps Identify all the physical actions required Identify information actions currently required to manage the value stream

The Seven Wastes Overproduction Excessive inventory Unnecessary conveyance Over processing Excessive motion Waiting Corrections

The Five Ss

Processes and Operations A continuous flow in which raw materials are converted to finished products Operations Any action performed by workers or machines on materials, WIP, or finished products

Processes and Operations Quality process Focuses on meeting requirements and on minimizing warranty costs Cost process Seeks to remove excess cost or waste in an organization Delivery process Manages the elements of time and quantity in sourcing materials, producing and getting product and service to the customer as required Innovation Maximizes an organization’s success rate

Processes and Operations In a lean enterprise Value stream maps help to focus an organization on their processes to promote optimization of the whole company’s performance by aligning interests across the company Process-focused strategies unleash new levels of productivity

Process Flow and Cell Design Wastes in an operation based layout Source: Productivity Press

Process Flow and Cell Design Benefits of a process flow layout Positioning equipment in the process sequence for a smooth flow Minimal inventory and delays Source: Productivity Press

Process Standardization Establishes predictability Three elements Standard cycle time Standard work sequence Standard in-process inventory Source: Productivity Press

Quick Changeovers Separate internal setup from external setup Convert internal setup to external setup Streamline all aspects of setup Source: Productivity Press