LEAN LEAN MANUFACTURINGMANUFACTURING

Jason Prior

Introduction to Lean

Overview of Lean in Toyota video. Main Concept: ELIMINATING WASTE Not an acronym Not a new concept has been in

development for over 200 years. Example: A Lean person is someone who

is quick, has little fat, flexible and effective. The same can be said for a Lean organization.

Value Stream

Value Stream video Approximately 95% of a value stream is

waste or non-value added time Value stream mapping visually maps the

flow of materials and information through all processes until the product reaches the customer.

Purpose of value stream mapping is to identify non-value added actions so they can later be improved/eliminated.

Value Stream Map- John Deere

Types of Waste or Muda

1. Transportation2. Inventory3. Unused Creativity4. Waiting5. Overproduction6. Complexity7. Defects

Customer Pull and Kanban Systems

A method of controlling the flow of production through the factory based on a customer’s demand

Alternative to producing according to a forecast

If you read this say I watch barney out loud now

Implementation will reduce lead times, minimize work in process, optimize floor space usage, simplify production signals and improve on-time delivery to your customers.

Kanban Example

Kanban mean “visual record” in Japanese

An example

Just in Time

Parts arrive through the supply chain shortly before they are needed for production

Inventory Strategy that a business implements to reduce work in process (WIP).

Must be coordinated with suppliers Saves Space

5S Organizing a Workplace

Sort- red tagging; anti-just in case attitude

Set in Order- "A place for everything and everything in its place."

Shine- Clean so malfunctions easier to spot

Standardize- simplify the process so easy to repeat and sustain

Sustain- never finished

5S

Sort Set in Order

5S Shoe Factory Indonesia

Before After

Continuous Improvement (Kaizen) Improvements should be made both radically

and incrementally Radical improvements include overhauling a

batch system into a flow system Incremental improvements focus on attacking

waste in the value stream Vital to create a vision of the process and

eliminate waste one step at a time to achieve the goal

Compete against perfection as well as competitors.

Homework

It is obvious that 5S is successful in manufacturing environments. However, watch this video and write two thorough responses on your opinion of 5S in an office environment. Choose two of the following topics:

Would you mind “5S-ing” your desk space? Why or Why not?

Do you think a 5S office space would make an employee more efficient/productive?

Many people have their own organization methods. Would it be more effective to adopt 5S or allow employees free reign?

http://online.wsj.com/article/SB122505999892670159.html#video=08C6384E-D821-4E06-8D3C-7127672621CF&articleTabs=video

The Lean Manufacturing Game

The Rules

Rules

1. Divide into 2 equal teams2. There will be 8 available questions to

choose from. The two teams will alternate choosing and answering questions.

3. 1st question =100 ; 2nd question=200; 3rd question =300 ; 4th question =400

4. If a team answers incorrectly the other team has the chance to steal the points

5. Each team gets one Super Question which adds 200 points to the question’s value.

Put Away All Materials Now

The Questions

Question 1 Question 2 Question 3 Question 4

Question 5 Question 6 Question 7 Question 8

Question 1

Name four types of waste in a Lean environment.

Answer

Question 2

The Toyota Production System was largely influenced by the Ford model. However, name an improvement made by Taiichi Ohno and the Japaneses that made the TPS much more effective.

Answer

Question 3

Briefly explain the concept of a pull system

Answer

Question 4

What is the overall concept of Lean in two words?

Answer

Question 5

Name the person accredited for perfecting interchangeable parts.

Answer

Question 6

What is the purpose of mapping a value stream?

Answer

Question 7

What is the definition of value added?Answer

Question 8

Name all 5 S’s in orderAnswer

Answer Question 1

1. Transportation2. Inventory3. Unused Creativity4. Waiting5. Overproduction6. Complexity7. DefectsMain Questions

Answer Question 2

JIT Working conditions Team development Cellular manufacturing Flexibility Kanban systems Quality circlesMain Questions

Answer Question 3

A method of controlling the flow of production through the factory based on a customer’s demand

Main Questions

Answer Question 4

Eliminate WasteMain Questions

Answer Question 5

Eli Whitney Main Questions

Answer Question 6

To identify non-value added actions so they can later be improved/eliminated.

Main Questions

Answer Question 7

Something the customer is willing to pay for.

Main Questions

Answer Question 8

SortSet in OrderShineStandardizeSustainMain Questions