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7/29/2019 Principles of lean manufacturing
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L E A N E N T E R P R I S E
Principles of Lean Manufacturing
Participant Workbook
7/29/2019 Principles of lean manufacturing
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Principles of Lean Manufacturing
L E A N
E N T E R P R I S E
Principles of Lean Manufacturing
By the end of this class you will be able to:
Define Lean
Identify the eight wastes
Differentiate between Value-Addedand Non-Value-Addedactivities
Apply various Lean implementation toolsin a simulation setting
Describe how Lean Principles can impact the successof yourorganization
Course Objectives
Orientation
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Product Catalog
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The Bottom Line
Sells for $4
Labor cost: $2.00/person/shiftFacilities cost: $10.00/table/shift
Sells for $4
Materials cost $0.50
Materials cost $0.50
Production Process Orientation1. Sales Representative Processes Customer Order2. Production Scheduler Generates Factory Order from forecast3. K it ter (s ) Organizes raw materials for Factory Orders4. Material Handler Moves product between ALL workstations
5. 1st OP Blue Initial folding: Blue6. 1st OP White Initial folding: White7. 2nd OP Blue Final folding : Blue8. 2nd OP White Final folding: White
9. In sp ec to r Assures Quality10. Warehouse/Ship Clerk Matches boats to Customer Orders11. Trucker Ships products to the customer12. Production Supervisor Supervises production13. Industrial Engineer Monitors production process
Production Facility Orientation
SalesOffice
ProductionControl
KittingArea
ReworkArea
1st OPBlue
InspectionArea
1st OpWhite
FinishedGoods Whse.
WIPStorage
2nd OPWhite
2nd OPBlue
ShippingDock
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Product Components Orientation
White Paper
Blue Paper
Product Routing
1 piece
1 piece 1 piece
1 piece
Production Batching
4 per batch
4 per batch
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Customerorder
forms
Factoryorderforms
FinishedGoods
Warehouse
Customerorders
(demand)
Productionforecast
Shipmentsto
customers
Production Scheduling Process
Customer Service Targets
4 minutes after order
4 minutes after order
All orders are filled f irst-in, first-out (FIFO)
Promised shipments to customers
Promisedshipments
tocustomers
Principles of Lean Manufacturing
Company Policies
All shifts are 10 minutes Keep busy at all times Yell if you need parts Handle all parts fir st-in, firs t-out (FIFO) Only the Material Handler can move parts Stay at your workstation The boss is alwaysright!
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Principles of Lean Manufacturing
Go to Work!
Round 1
Principles of Lean Manufacturing
Discuss results
How did it feel?
Relationship to real world
Round One: Debrief
Principles of Lean Manufacturing
Introduction to
Lean
Manufacturing
Principles of Lean
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Principles of Lean Manufacturing
LEAN is: A systematic way to deliver the
GOOD
CHEAPFAST
PICK ANYTWO
9highest quality,9lowest cost productswith the9shortest lead-timesthrough the
9relentless elimination of waste.
Defining Lean
Principles of Lean Manufacturing
Value Added
Any activity that changes the market form orfunction of the product or service
Things the customer is happy to pay for.
Non-Value Added
Any activity that does not change market form orfunction
(although it may be necessary)
These activities should be eliminated, simplified,
reduced, or integrated when possible.
Definition of Value-Added
Principles of Lean Manufacturing
Non-Value-Added
Defects
Overproduction
Waiting
Non-Value Added Processing
Transportation
Inventory
Motion
Employees: KSAs(Knowledge, Skills and Abilities)
Value-Added
Lean = Eliminating Waste
Typically 95%of all lead time is non-value-added.
5%
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Principles of Lean Manufacturing
Defects in the Factory
Inspection and repair of product
Causes of defects
- Weak process control
- Poor quality system
- Deficient planned maintenance
- Inadequate education/training/work instru ctions
- Poor product design
- Customer needs not understood
Principles of Lean Manufacturing
Overproduction in the Factory
Making more product than is required by the next process
Making product earlier than is required by the next process
Making product faster than is required by the next process
Causes of overproduction
- Just-in-case logic
- Long process setup (encourages large lot runs)
- Unbalanced workload (WIP)
- Poor communication
- Misuse of automation
Principles of Lean Manufacturing
Waiting in the Factory
Idle time created when waiting for?
Causes of waiting waste
- Unbalanced workload- Unplanned maintenance
- Long process setup times
- Poor suppliers
- Upstream quality problems
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Principles of Lean Manufacturing
Non Value-Added Processing in the Factory
Effort that adds no value to the product or service from thecustomers viewpoint
Causes of processing waste
- Product changes without process changes- Just-in-case logic
- True customer requirements not clearly defined
- Lack of communication
Principles of Lean Manufacturing
Transportation in the Factory
Transporting parts and materials around th e plant
Causes of transportation waste
- Poor plant layout
- Poor understanding of
production process flow
- Large batch size, long lead
times, large sto rage areas
Principles of Lean Manufacturing
Inventory in the Factory
Any supply in excess of a one-piece flow through yourmanufacturing process
Causes of excess inventory
- Misconception that this protects the company from
inefficiencies and unexpected problems- Product complexity
- Poor market forecast
- Unbalanced workload
- Misunderstood communications
- Reward systems
- Unreliable shipment by suppliers
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Principles of Lean Manufacturing
Motion in the Factory
Any movement of people or machines that does not addvalue to the product or service
Causes of motion waste
- Poor people/machine interface
- Inconsistent work methods
- Unfavorable workstation or cell layout
- Poor workplace organization and housekeeping
Principles of Lean Manufacturing
Employee KSAs in the Factory(Knowledge, Skills and Abi lities)
The waste of not using peoples mental, creative, andphysical abilities
Causes of people waste
- Old guard thinking, politics, the business culture
- Poor hiring practices
- Low or no investment in training
- Low pay, high turn-over strategy
Principles of Lean Manufacturing
What wastes were apparent?
Brainstorm Wastes
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Principles of Lean Manufacturing
Lean Building Blocks
Quick Set-up
Standardized Work Lot Size Reduction Teams
Quality at Source
5S System Visual Plant Layout
POUS
Cellular FlowPull / Kanban TPM
ValueStreamMapping
Continuous Improvement
Principles of Lean Manufacturing
Mass Production
Testing
Value-Added Time : MinutesTime in Plan t : Weeks
ReceivingWarehouse
Kitting
1st OPWhite
2nd OPBlue
Storage
Repair Inspection
ShippingWarehouse
Ship
Material
ORDER CASH
2nd OPWhite
1st OPBlue
Principles of Lean Manufacturing
9Createsa safe, clean, neat arrangement of the workplace
9Providesa specific location for everything
9Eliminatesanything not required
Work Place Organization (5S)
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Principles of Lean Manufacturing
Elements of a 5S Program
5. Susta in
1. Sort
4. Standardize
3. Shine
2. Set in Order
Principles of Lean Manufacturing
5S: Starts With Cluttered Areas
Elements of a 5S Program
Principles of Lean Manufacturing
Ends Up With Organized Areas
Elements of a 5S Program
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Principles of Lean Manufacturing
Example:Local Tool Board
Elements of a 5S Program
Principles of Lean Manufacturing
Defines operations safely carried out with all tasks organized inthe best known sequence using the most effective combinationof these resources:
People
Materials
Methods
Machines ConsistentProcess
DesiredResults
InconsistentProcess
InconsistentResults
Without Standardized Work there can be no sustained improvements
Standardized Work
Principles of Lean Manufacturing
Traditional Plant Layout
N/C
Lathes
Tool
Crib
Sheet MetalCentral
Inspection
N/C
Mills
Manual
Mills
Manual
Drills
ToolCrib
Degrease
Machine
Assembly Stock/Staging
Deburr
Plastics
N/C
MillsN/C drill
Jigbore/
EDMGrind
Saws Shears
Raw StockManual Lathe
Silver
Solder
Receiving
Finishing
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Principles of Lean Manufacturing
Product Cell
Manual
Mills
Manual
Drills
Degreas Machine
Assembly
Stock/
Staging
Deburr
N/C drill Raw Stock
Silver
Solder
Principles of Lean Manufacturing
Teams
3Members rotate between highly specified jobs
Cross-trained and multi-skilled employees
9 Operators can work many operations within a celland operations in different cells
A foundation of the continuousimprovement philosophy
Lean Workforce Practices
Principles of Lean Manufacturing
What needs to change?
5S SystemStandardized Work
Visual ControlsPlant Layout
TeamsPOUS
Batch Size Reduction
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Principles of Lean Manufacturing
Go to Work!
Round 2
Principles of Lean Manufacturing
Discuss results
How did it feel?
Relationship to real world
Round Two: Debrief
Principles of Lean Manufacturing
Quick Changeover
Standardized Work Batch Reduction Teams
Quality at Source
5S System Visual Plant Layout
POUS
Cellular/FlowPull/Kanban TPM
Continuous Improvement
ValueStreamMapping
Lean Building Blocks
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Principles of Lean Manufacturing
10 minutes
10 minutes
Batch & Queue Processing
Lead Time 30+ minutes for total order
21+ minutes for first piece
10 minutes
ProcessA
ProcessB
ProcessC
Process
BProcess
AProcess
C
Continuous Flow Processing
12 min. for total order
3 min. for first part
Impact of Batch Size Reduction
Principles of Lean Manufacturing
Batch Size Reduction
The best batch size is one piece flow,
or
make one and move one!
Principles of Lean Manufacturing
SET-UP:The time required to remove the old tools,dies or fixtures; attach new tools, dies or fixtures andrun the machine until a new part, without defects, is
produced.
Run Run
Part
Set-uptime
Firstgoodpart
1st
pieceinspection
Changeover
Completion
of last good
part
Locate
tools, dies
or fixtures
Clean, sanitize,
attach new
tools, dies or
fixtures
Make
Ad
justme
nts
Make
Ad
justme
nts
Removeold tools,
dies orfixtures
Set-up Definition
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Principles of Lean Manufacturing
Linking of manual and machine operations into the mostefficient combinatio n to maximize value-added content whileminimizing waste.
1st OP
2nd OP
Inspection
3rd OP
Shipping
4th OP
Cellular Manufacturing
Raw Material
Principles of Lean Manufacturing
Push System
Based on forecasts or schedules
Pull System
Production and resource flow based on actualconsumption
3Small lots
3Low inventories
3Visual management
3Better communication
Push vs. Pull Systems
Principles of Lean Manufacturing
Continuous Improvement
Pull System Flow Diagram
Information Flow
Supplier
RawMatl
ProcessA
ProcessB
Fin.Goods
KanbanLocations
ProcessC
Customer
Parts Flow
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Principles of Lean Manufacturing
Quick Changeover
Standardized Work Batch Reduction Teams
Quality at Source
5S System Visual Plant Layout
POUS
Cellular/FlowPull/Kanban TPM
Continuous Improvement
ValueStreamMapping
Lean Building Blocks
Principles of Lean Manufacturing
What needs to change?
Batch Size ReductionPOUS
5S SystemStandardized WorkVisual Controls
Plant LayoutTeams
TPM
Quick Changeover
Cellular Flow
Pull/Kanban
Quality @ Source
Principles of Lean Manufacturing
Go to Work!
Round 3
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Principles of Lean Manufacturing
Discuss results
How did it feel?
Relationship to real world
Round Three: Debrief
Principles of Lean Manufacturing
Implementation
Value Stream Mapping
Train workers with appropriate skills
Solve problems using Lean tools
Continuous Improvement
Action Plan
Principles of Lean Manufacturing
Quick Changeover
Standardized Work Batch Reduction Teams
Quality at Source
5S System Visual Plant Layout
POUS
Cellular/FlowPull/Kanban TPM
Continuous Improvement
ValueStreamMapping
Lean Building Blocks
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Principles of Lean Manufacturing
Can you now:Define Lean?
Identify the eight wastes?
Differentiate between Value Addedand Non-Value Addedactivities?
Apply various Lean implementation toolsin a simulation setting?
Describe how Lean Principles can impact the successof yourorganization?
Course Objectives
Principles of Lean Manufacturing
Benefits of Lean
Lead Time
0 25 50 75 100
Percentage of Benefits Achieved
Productivity Increase
WIP Reduction
Quality Improvement
Space Utilization
Principles of Lean Manufacturing
Continuous Improvement (CI)
Old Adage:
If you always do what you always did, youll alwaysget what you always got.
Competitive Corollary: If the other g uy gets BETTER, youre gon na get LESS.
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Thank You.
L E A N
E N T E R P R I S E
Principles of Lean Manufacturing
Recommended Readings
Lean Thinking by Jim Womack
Becoming Lean by Jeffrey Liker
The Machine That Changed the World by Jim Womackand Daniel T. Jones
The Goal by Eli Goldratt
World Class Manufacturing: The Next Decade byRichard Schonberger
Lean Production Simplified by Pascal Dennis
Others can be found on bookstore sites key word
Lean
Principles of Lean Manufacturing
Lean Web Sites
MEP Lean Sites:
www.techhelp.org
www.mepcenters.nist.gov
Other Lean Sites:
www.lean.org
www.productivityinc.com
www.superfactory.com
www.nwlean.net
www.sme.org
www.apics.org