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A program of the Hawaii Technology Development Corporation
For reference only
A program of the Hawaii Technology Development CorporationA program of the High Technology Development Corporation
Lean Process Improvement for Scaling Up Your Operations
May 4, 2019Hawaii Small Business Fair
A program of the Hawaii Technology Development Corporation
For reference only
Who am I?
•Wayne Layugan
•Email: [email protected]
•Phone: 808.539.3702
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
Who am I?
•Erin Furuichi
•Email: [email protected]
•Phone: 808.539.3621
A program of the Hawaii Technology Development Corporation
For reference only
Innovate Hawaii• Program of Hawaii Technology
Development Corporation (HTDC)
• Public-private partnership that delivers solutions to U.S. manufacturers
• Training programs
• Manufacturing Assistance
• Advancing manufacturing in Hawaii
Create. Build. Grow.
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
What does Lean mean to you?
A program of the Hawaii Technology Development Corporation
For reference only
Definition of Lean
• relentless removal of wastefulactivities, and
• the simplification & standardization of manufacturing and support processes
A set of principles and practices whichreduce cost through the. . .
. . . throughout the entire enterprise.
A program of the Hawaii Technology Development Corporation
For reference only
The Value Stream
Non-Value Added ActivityThose activities that take time or resources, but do
not directly contribute to the product/service.
Value Added ActivityAn activity that changes the fit, form, or function, done
right the first time and is something the customer is willing to pay for.
A program of the Hawaii Technology Development Corporation
For reference only
Define Value Added
Non-Value Added Activity (NVA)Pick an activity. If you STOP doing it now would any customer (internal or external) know the difference. If not, probably NVA.
Value Added Activity (VA)If it’s not clear whether a task is Value Added, imagine what would happen if you STOP doing it. Would your external or end customer complain. If yes… VA.
Non-Value Added but necessaryIf you STOP doing it now, would your internal customer complain? If yes, probably NVA but necessary.
A program of the Hawaii Technology Development Corporation
For reference only
Common Mistake50% Improvement of VA Time
NVA
VA VA
NVA
Dr. Deming: 94% of the problem is the system, 6% is the people!
A program of the Hawaii Technology Development Corporation
For reference only
Why Focus on Waste50% Improvement of NVA Time
VANVA
VA
NVA
A program of the Hawaii Technology Development Corporation
For reference only
Lean – Eliminating the Eight (8) WastesValue Added
Typically 95% of all lead time is non-value added
Non-Value Added • D e f e c t s• O v e r p r o d u c t i o n• W a i t i n g• N o n - u t i l i z e d Ta l e n t
• Tr a n s p o r t a t i o n• I n v e n t o r y• M o t i o n• E x c e s s i v e P r o c e s s i n g
A program of the Hawaii Technology Development Corporation
For reference only
Lean Applies To…
Product development (Engineering)
Order taking and scheduling
Manufacturing
Logistics
Administrative systems
Human Resources
………..EVERYTHING!
A process is a Process is a Process
A program of the Hawaii Technology Development Corporation
For reference only
VA vs NVA example
Does the operator have to do all the non-value
added work?
Value – Added
• Blade cuts wood
IncreaseValue-Added
Non - Value – Added
• Handling wood• Clean up• Quality checks• Banding bundles• Moving bundles of wood• Changing blades• Breaks / Lunch• Meetings• Breakdowns• Adjusting saw• Paperwork• Waiting for wood• Waiting for helper to return
wood for additional cut
ReduceNon-Value-Added
A program of the Hawaii Technology Development Corporation
For reference only
Lean ManufacturingBuilding Blocks
Quick Changeover
Standardized Work
Batch ReductionTeams
Quality at Source
Line Balancing
Visual Controls
Plant Layout
POUS
Cellular/FlowPull System / Kanban
Total Productive Maintenance
ValueStreamMapping
8 Wastes / 5S Systems
Takt Time
Continuous Improvement
A program of the Hawaii Technology Development Corporation
For reference only
The 5S Systems• Workplace organization method • Developed in Japan
• Seiri (Sort)• Seiton (Set In Order)• Seiso (Shine)• Seiketsu (Standardize)• Shitsuke (Sustain / Self-discipline)
• Technique that enabled Just-In-Time Manufacturing aka Toyota Production System(TPS)
• Foundation for continuous improvement
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
The 5S Numbers Company
A program of the Hawaii Technology Development Corporation
Orientation• All shifts are 20 sec.• Task is to strikeout
numbers 1 to 49 in correct sequence
Example: 1 2 3…/ / /
A program of the Hawaii Technology Development Corporation
For reference only
Standardized Work Standard Pig Exercise
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
How can a plate of
spaghetti help Lean your process?
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
Process Flow – Spaghetti Diagram
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
Process Flow – Ideal Layout
• Little to no overlap
L-shaped
S-shaped
U-shaped
A program of the Hawaii Technology Development Corporation
For reference only
What does Lean mean to you?
Productivity Quality Costs Profitability
+ + =
A program of the Hawaii Technology Development Corporation
For reference only
Batch Size Reduction
Post It Note Exercise
A program of the Hawaii Technology Development Corporation
A program of the Hawaii Technology Development Corporation
For reference only
Thank you for attending!
A program of the Hawaii Technology Development Corporation