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©2012-2013, IL Holdings, LLC
All rights reserved 1
LEAN CONCEPTS
The Thinking Approach
©2012-2013, IL Holdings, LLC
All rights reserved 2
TECHNICAL THINKING TO
DEVELOP A LEAN SYSTEM
Tools to Drive Kaizen Activity
©2012-2013, IL Holdings, LLC
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TECHNICAL TOOLS
Tools to
Improve
Tools to
Measure
Two key questions
UNDERSTANDING SKILLS
When do I need them? What are they?
LEAN TRANSFORMATION
©2012-2013, IL Holdings, LLC
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TOOLS TO IMPROVE
Stability
Problem Solving
Standardized Work
Jidoka
Heijunka
©2012-2013, IL Holdings, LLC
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JIDOKA
TOOLS TO IMPROVE
©2012-2013, IL Holdings, LLC
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BUILD IN QUALITY
× Only inspect finished goods
× No feedback to operations
generating the defects
× Extra rework operation / cost
JIDOKA
A C B
Rework
Scrap
Ship
Inspect
C B A
Traditional Thinking
©2012-2013, IL Holdings, LLC
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BUILD IN QUALITY
Do not pass defects – fix in
process
Immediate quality feedback
Defects are found at the source
Each Process only
ships quality product
C
A
B A
C B
Ship
JIDOKA
Lean Thinking
©2012-2013, IL Holdings, LLC
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HOW WE BUILD IN QUALITY
1. Make abnormalities visible
2. Call for help quickly
3. Immediate response
4. Implement countermeasure
2
Call for help
Quick
Response
3
Countermeasure 4
1
JIDOKA
©2012-2013, IL Holdings, LLC
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TOOLS TO BUILD IN QUALITY
Developed from supervisors need to
know when / where problems occur
Tool for visual control
Practical, easy, inexpensive
Team member input
Go and see!
ANDON POKAYOKE Human
[Flag]
Machine
[Light]
Fixture
JIDOKA
©2012-2013, IL Holdings, LLC
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SEPARATE MAN FROM MACHINE
1 Man – 1 Machine
1 Man – Several Machines
Unclamp Clamp
MAN MACHINE
Wait on
machine
Unclamp Clamp
MAN
MACHINE
Unclamp Clamp
MAN MACHINE
One cycle time
Turret A
Turret B
JIDOKA
©2012-2013, IL Holdings, LLC
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JIDOKA EXAMPLE
JIDOKA
©2012-2013, IL Holdings, LLC
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WHY JIDOKA MATTERS
PROCESS
Call for help
Quick
Response
Countermeasure
1
2
3
4
Build in quality
More effective use of
human resources
Highest Quality
Lowest Cost
Shortest Lead Time 1 Man – 1 Machine
1 Man – Several Machines
Unclamp Clamp
MAN MACHINE
Wait on machine
Unclamp Clamp
MAN
MACHINE
Unclamp Clamp
MAN MACHINE
On cycle time
Turret A
Turret B
JIDOKA
©2012-2013, IL Holdings, LLC
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QUESTIONS
CLOSING DISCUSSION