3-Intro to Lean t2

Development of Maintenance

European Maintenance Std.

Benchmarking

Maintenance Models

- RCM

- KZMG

- Integration Model - TPM

- Methods to Optimisation

- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop

Compiled By:Rudolf Schenker PMP Pr.Tech.Eng., Reg.Eng.TechMTECH.- Mech. Engineering

© All Rights Reserved 2009

1/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce

Future State Reinforce

Current State Reinforce

Introduction To

Lean Techniques

Introduction to Lean Techniques

Production History Craft Production Mass Production Lean Manufacturing

Statistics Systems Approach 8 Lean Principals



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



2/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



History: From Craft to Mass to Lean Production



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



3/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Ford History: 1913 vs 1914 Production Improvement

Component 1913 Craft ProductionCycle Time (min.)

1914 Mass ProductionCycle Time (min.)

% Improvement

Engine 594 266 62%

Magneto 20 5 75%

Axle 150 26.5 83%

Major Components

750 93 88%

1908Cycle Time514 min.

1913Cycle Time2.3 min.

1913Cycle Time1.19 min.



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



4/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Industrial Reflection of Effective Plant Utilization

56,3 4,5 12,6 12,3 14,3

31,900,5

12 55,7

60,51 6,8

22,3 9,5

61,32,2 4,6

16,7 15,3

59,6 49,9

23,9 2,6

57,52,4 2,8

21,4 16

0% 20% 40% 60% 80% 100%

Mec

hani

cal E

ng.

Aut

omot

ive

Effective Plant Utilization Quality LossesMaterial flow- &. C/Over Losses Availability LossesCapacity Losses



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



5/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Effects of Lean Techniques

Performance Japanese in Japan

Japanese in N.USA

Americans in N.USA

All Europe

Training of new workers (h)

380.3 370 46.4 173.3

Productivity (h/vehicle) 16.8 21.2 25.1 36.2

Quality (assembly defects/100 veh.) 60 65 82.3 97

Inventories(days of 8 samples) 0.2 1.6 2.9 2.0

% Workforce in teams 69.3 71.3 17.3 0.6

CIP - KAIZEN(Suggestions/Employee) 61.6 1.4 0.4 0.4

Job Classes (Levels of Hierarchy) 11.9 8.7 67.1 14.8

Job Rotation(0=none; 4=frequent) 3 2.7 0.9 1.9

Absenteeism 5 days 4.8 days 11.7 days 12 days

Source: IMVP World Assembly Plant Survey 1989 & JD Power initial Quality Survey 1989



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



6/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Systems Approach to Lean Thinking



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



7/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



No MUDA

The 7 types of WASTE to Combat:

1. Over Production

2. Idle Time

3. Transport

4. Processing

5. Parts/Material

6. Industrial Engineering

7. Re-Work What is

Waste?



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



8/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



KANBAN - JIT

Japanese for “card” or “ticket”, KANBAN is used in a PULL-System to improve flow to authorize production and movement of goods. It is a card which indicates standard quantity of production.

Two types of KANBAN are being used:1.“Production-Kanban” are located at the end of the production area where the part is produced. 2.“Move-Kanban” are located at the start of the production area.

Source: http://www.leaninstitute.in



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



9/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Just In Time – JIT – 6R

A system for producing and delivering the right Items at the right Time in the right Amounts..

The Key Elements are:1.Flow2.Pull3.Standard Work4.Takt Time


5S & 7 Muda Application



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



10/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



POKE YOKE


A system driven by unique engineering, design and innovation to prevent parts from being fitted or assembled incorrectly.

Do it RIGHT1St Time!!



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



11/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



1.Sort

2.Set in Order (Stabilize)

3.Shine

4.Standardise

5.Sustain

5 S Lean Thinking

Source: Lean Thinking – James P. Womack & Daniel T. Jones



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



12/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



System / Process Kaizen

Work / Task Kaizen

Top Management

Org. Entry Level

Focus

Plan

DoCheck

Act

AvoidStagnation

KAIZEN

KAIZEN is a concept that promotes a Continuous Improvement Process.



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



13/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Jidoka

"Auto(no)mation" or "automation with a human touch." Jidoka does not allow defective parts to go from one work station to the next. Machine can be made to stop automatically in abnormal conditions .

Source: Siemens & http://www.leaninstitute.in

CMMS CBM Production Management

MRP?BAAN JD.E

P.Soft

QC



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



14/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



A major and radical improvement done at an entire system level or value stream level or a major re-layout, or a process change, or a major modification of equipment, jigs or fixtures. The Kaikaku exercise requires detailed planning and well coordinated action in a short time window and can be used as an effective tool to overcome system inertia as well

KAIKAKU

Source: CDG & http://www.leaninstitute.in

Plant Design Layout Shortest Route Inventory

Process Design Product Design Tool Design

RAPID TECHNOLOGIES CAD CAM FEM Simulation Prototyping Tooling Quick 1st Batch



Benchmarking

Maintenance Models

- RCM

- KZMG



- Introducing CMMS

Intro To Lean

Lean Toolbox

VSM Case Studies

Intro to VSM

VSM Workshop



15/15

Welcome & Intro

Lean in Action

VSM Current State

VSM Future State

Lean Reinforce



Documents

3-Intro to Lean t2