1. Review of Lean Topics
Dewey Warden

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

3. 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.

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

5. 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?

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

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

8. The Five Ss

9. 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

10. 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

11. 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

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

13. 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

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

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