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Lean 101 Lego Lean Orientation Lean Overview – The Basics…… Presented By: Bill Stockstill – TMAC Panel Members Rosina Wittmeyer – DRS Infrared Technologies, LP Bob Brunett – Bell Helicopter Textron Mike Navaira – Lockheed Martin Aeronautics

Lean 101 Lego Lean Orientation

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Page 1: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Lean Overview –The Basics……Presented By: Bill Stockstill – TMAC

Panel MembersRosina Wittmeyer – DRS Infrared Technologies, LP

Bob Brunett – Bell Helicopter TextronMike Navaira – Lockheed Martin Aeronautics

Page 2: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

• Texas Manufacturing Assistance Center

• Our Mission:

– Improve the global competitiveness of Texas’ Manufacturers by applying the appropriate techniques and technologies.

• TMAC is part of the MEP System

TMAC works closely with Manufacturing Supply Chain to make them more competitive by providing assistance in appropriate use

of technologies and techniques

What is TMAC?

Page 3: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

TMAC Services

• Management Controls, Systems, and Compliance– Planning & Policy Deployment– Financial Controls and Measurement Systems– EPA, OSHA– QMS, EMS, SMS

• Culture and Workforce Development– Supervisor and Technical Training– Teams/Team Facilitation

• Waste and Variation Reduction– Lean and Six Sigma– TPM– EHS– Facility Design and Relocation

• Technology Application– ERP, MRP– Automation & Mechanization

Page 4: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Cycle Time

“One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost.”

Henry Ford, 1926

Page 5: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Mass Production

Value-Added Time : MinutesTime in Plant : Weeks

ReceivingWarehouse

Kitting

Springs Diodes

Storage

Repair

Testing

ShippingWarehouse

Ship

Material

ORDER CASH

LEDs

Page 6: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Defining Lean

“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.”

The MEP Lean Network

Lean has been defined in many different ways.

Page 7: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Definition of Value Added

Value Added

Any activity that increases the market form or function of the product or service. (These are things the customer is willing to pay for.)

Non-Value Added

Any activity that does not add market form or function or is not necessary. (These activities should be eliminated, simplified, reduced, or integrated.)

Page 8: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Lean = Eliminating the Wastes

Value Added

Typically 95% of all lead time is non-value added

• Defects

• Overproduction

• Waiting / Busy Work

• Non Value Added Processing

• Transportation / Conveyance

• Inventory

• Motion

• Employees Underutilized

Non-Value Added

Page 9: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Benefits of Lean

Lead Time Reduction

0 25 50 75100

Percentage of Benefits Achieved

Productivity Increase

WIP Reduction

Quality Improvement

Space Utilization

Page 10: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

Lean Strategic Initiative Elements

• Burning Platform – Operational Excellence as Key Strategy• Defined Roles and Responsibilities

– Management Sponsored and Driven– Mid-Management Fueled– Grass Roots Implemented

• Wide Spread Orientation• Formal Launch

– Need for Change– WIFM– Management Expectations – Layoff Policies

• Requires Management System– Regular Progress Checks– Communication– Integrated Measurements– Recognition and Rewards– Project Management

• Team Culture• Proposal System

Strategic Planning

Lean 6 sigma

ResourceAccounting

WorkForceDevelp

Page 11: Lean 101 Lego Lean Orientation

Lean 101 LegoLean Orientation

For More Information...

Mark Sessumes (817)312-5853email: [email protected]

Bill Stockstill (817)917-2564email: [email protected]