2. 5S and Visual We consider 5S and Visual Controls to be the foundation of Lean Manufacturing systems. 5S and Visual Controls are workplace organizational tools that provide the necessary groundwork for workplace improvement. 5S and Visual Controls ensure that there is a place for everything and that everything is in its place—clean and ready to use.

3. Pre-5S … Scrounge Steal Stash Scramble Search

4. Lean Manufacturing team will educate the members in 5S and support them during the implementation of a pilot project. This project can be replicated in other areas. This education teaches employees to be self-directed and to adopt Lean Manufacturing throughout your facility. A team-based corporate culture that empowers your workforce and instills the desire for continuous improvement.

7. Benefits of 5S Improve safety Decrease down time Raise employee morale Identify problems more quickly Develop control through visibility Establish convenient work practices

8. Benefits of 5S….. Increase product and process quality Strengthen employees’ pride in their work Promote stronger communication among staff Empower employees to sustain their work area

10. Kaizen Workshop Goals Radical reductions in business-process cycle times, increased throughput, elimination of waste and bottlenecks, and improved morale and safety can be achieved rapidly and cost effectively.

11. About the Kaizen Workshop This three-day workshop is based on "rapid cycles" or "bursts" of education, followed by immediate application of the concepts learned.

12. Results Successful workplace improvements are best measured by results and the cycle time taken to achieve breakthrough performance.

13. Examples of some recent Kaizen workshop improvements include : · Parts Travel Distance25 - 92% · Finished Goods Inventory13 - 67% · Space Reduction25 - 78% · Work-In-Progress Inventory60 - 92% · People Travel Distance33 - 78% · Productivity Gains 15 - 45% · Product Cycle Time 5 - 35%

14. The Kaizen workshop includes: Focusing on a predetermined, specific area Training in Lean Manufacturing principles and methodologies Benchmarking your "Current State" and Process Mapping Developing a "Future State" vision Implementing your new vision rapidly Measuring the achieved results Creating multi-disciplined teams, comprised of a cross section of shop floor operators, management and support staff, working together to achieve accelerated and dramatic change to your business processes and operating results

16. Quick Changeover " Increase Your Productivity and Quality While Reducing Your Lead Times and Inventories"

17. Your operation can benefit from Quick Changeover techniques if you are experiencing any of the following problems: Frequent schedule changes causing excessive set-up costs Unacceptable delivery, lead times, and customer satisfaction Excessive in-house manufacturing cycle times causing the sales forecast horizon to be too far in the future to be reliable Inability to produce small customer orders without charging for set-ups

18. Quick Changeover techniques… Exorbitant raw material and work-in- process inventories Wasted floor space to store WIP inventories Justifying funds to rent/buy additional warehouse space, racks, lift trucks and indirect labour

19. How Quick Changeover Works Train the set-up team(s) in quick set-up techniques that will enable them to reduce set-ups on any piece of equipment in your plant. Teams normally experience a minimum of 50% reductions!

20. Results In many organizations, the reduction of set-up can be the key to improved productivity, customer service, and inventory reduction. We have helped numerous clients achieve dramatic reductions in areas such as: W.I.P. Inventory Factory lead times Factory floor space requirements

22. Plant Layout Reducing manufacturing costs through improved plant layout is an effective way to improve profitability Lean Manufacturing can radically reduce costs within your manufacturing facility.

23. Then... Former manufacturing improvement efforts focused on direct labour costs only. The problem with this approach was that these costs represent only 5-15% of the total manufacturing costs.

24. Now... Lean Manufacturing Solutions Inc. focuses on both direct and non-direct labour costs as well as material flow and inventory turns. This results in savings in all three key areas: Materials Overhead Direct Labour

25. Improved plant Layout = Increased Profitability "The great sense of accomplishment that the layout team members will have is exceeded only by management's satisfaction that the revised layout resulted in more than double the capacity in the same space."

27. Cellular Manufaturing Case for Cellular The following case demonstrates how the implementation of Cellular Assembly and Kitting resulted in breakthrough performance.

28. Goal The initial goal was to improve productivity by 50% through the use of our Kaizen Program workshop

30. Key Measurement Areas Parts travel distance Throughput time Work in process Manufacturing space requirements

31. Reductions Achieved Reduced by 85% Reduced by 99% Reduced by 93% Reduced by 40%