1. Lean Manufacturing Chapter 15 pp. 438-466 June 29, 2012

2. Lean Manufacturing Definition – Elimination – Waste – Continuous improvement 3 pronged approach – “Relentless” focus on quality – Eliminate waste – Involve employees

3. Lean Manufacturing “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.”

4. Lean Manufacturing Key principles – Value – Value stream “mapping” – Flow – Pull – Perfection culture

5. Lean Manufacturing Benefits – Lead time reduction – WIP reduction

6. 1 day 2 days 1 day 14 days 45 minutes 60 minutes 30 minutes

7. Lean Manufacturing Benefits – Lead time reduction – WIP reduction – Quality improvement – Space utilization – Greater customer satisfaction

8. “A systematic approach to identifying and eliminating….” Value stream mapping

9. “A systematic approach to identifying and eliminating….” Value stream mapping

10. “…waste (non-value added activities) …” 8 wastes of lean – Overproduction – Inventory – Waiting – Defects – Extra processing – Excessive motion – Transportation – Underutilized employees

11. “…waste (non-value added activities) …” 8 wastes of lean – Overproduction – Inventory – Transportation – Excessive motion – Extra processing – Defects – Waiting – Underutilized talents

12. “non-value added activities” Value-added activities – Transforms or shapes material or information – Customer wants it – Done right the first time Machining Assembly Painting Sewing

13. “non-value added activities” Non-value added activities – Consume resources but create no value for customers – Could be stopped and it would be invisible to the customer

14. “…through continuous improvement …” kaizen Satisfying the customer People = most important resource Quality at the source

15. “…through continuous improvement …” 5S’s – Sort – Stabilize (set in order) – Shine – Standardize – Sustain

16. (Stabilize)

17. Stability

20. Traditional layout Cellular layout

21. Stability LatheMillMill Inspect Drill Drill TestDrillPack 12345 10987 6 27 Seconds 27Seconds Inspect

22. (Stabilize)

23. “…by flowing the product at the pull of the customer…” Just-in time – Pull system (vs push) – Quick changeover (Set-up Reduction)

24. “…by flowing the product at the pull of the customer…” Pull system – Production based on actual consumption – Small lots – Low inventories – Management by sight – Better communication

25. Pull System Kanban

26. Pull System Kanban Supermarket

27. Quick Changeover (Set-up Reduction) Single minute exchange of dies (SMED)

28. Quality at the Source Source inspection Means to inspect Samples or established standards Process documentation Mistake proofing

30. Quality at the Source Source inspection Means Samples or established standards Process documentation Mistake proofing Andon

33. Standardization Standardized work

35. Involvement Teams –with rotation of highly specified jobs Cross trained/multi-skilled employees –can work many operations within a cell and operations in different cells

36. Stability LatheMillMill Inspect Drill Drill TestDrillPack 12345 10987 6 27 Seconds 27Seconds Inspect

37. Involvement Teams –with rotation of highly specified jobs Cross trained/multi-skilled employees –can work many operations within a cell and operations in different cells Continuous improvement philosophy Process quality, not inspection Use of participatory decision making

38. Why do it? Reduced inventory Improved quality Lower costs Shorter lead time Increased productivity Greater flexibility Greater customer satisfaction

39. Last comment Lean and Six Sigma “hand and glove”