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Ten Steps to Lean Production. Steps to CIM. Re-engineer (revisit, replan) the manufacturing system Form U-cells to produce families of parts (clusters) Integrate production, inventories, Quality Control and machine tools. Steps to CIM. Setup reduction or elimination - PowerPoint PPT Presentation
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Ten Steps to Lean Production
Steps to CIM
1. Re-engineer (revisit, replan)
the manufacturing system• Form U-cells to produce
families of parts (clusters)
• Integrate production, inventories, Quality Control and machine tools
Steps to CIM
2. Setup reduction or elimination
• Identify elements that are “internal” and those that are “external”
• Improve methods (use a pit crew)
• Re-engineer to eliminate adjustments, mechanize, automate
Steps to CIM
3. Integrate quality control into the system
• Develop a systems approach
• Incorporate visual signals• Work toward a “1 piece
flow” Make 1, check 1, move 1 on
Steps to CIM4. Integrate preventative maintenance
into the system• Reduce pressure on workers and the
process (back off from 100%)• Housekeeping – place for everything
and everything in place• Decrease system variability
Learning Loops in CIM
Steps to CIM
5. Level, balance, sequence and synchronize
• “Smooth” manufacturing• Keep production “level”• Make production “predictable”• Incorporate “kanban” labelling
Label
Steps to CIM6. Production Control
• Integrate scheduling and control functions into the system
• Use MRP/ERP software • Use the PC system to link cells together
• MRP = Manufacturing• ERP = Enterprise• DRP = Distribution• CRP = Capacity• BRP = Business
Schematic factory layout
Steps to CIM7. Reduce work-in-process
• Excess inventories hide problems• Reduce the inventory to expose problems• Take immediate action to eliminate the
problems
Steps to CIM8. Integrate suppliers
• Work to reduce suppliers to a single source
• Develop trust & open communications• Implement flexible procurement (supply
purchasing) contracts• Develop long-range forecasts
Steps to CIM9. Automation
• Allow workers to control the process (trust in work force)
• Provide clear directions• In-process controls and inspections• Feedback loops
Steps to CIM10. Computer-Integrated
Manufacturing• Enterprise-wide systems• Remove functionality
(independence) of departments• Focus teams on product lines and
customers
The REAL Goal is to become LEAN
• Waste eliminated• Employees involved• Customers satisfied• Profits increased• Company survival assured
By printing and binding in the same factory, Butler and Tanner reduces the amount of transport required during the production process
Achieving CIM• Toyota has been on a
“journey” toward a waste free and coordinated operation for 45 years… and they know they are not there yet.
• The “steps” and “tools” help people understand the process of change, but there is much more that is required
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