For the Customer For the Employee For the Company 1) Work Satisfaction 2) Job Security 3) Consistent Income 1) Market Flexibility 2) Profit (= Sales Price - Cost) 1) Highest Quality 2) Lowest Cost 3) Shortest Lead-time "Customer 1st" "Respect for Humanity" "Elimination of Waste (Muda)" ...by aiming for 100% creative effort ...by providing development ...by providing challenges ...by mutual trust with management ...in Man, Material, Method or Machine ...in areas of over-producing, waiting, conveyance, processing, inventory, motion, correction ... is the principle of considering the need and desires of the customer when determining direction and strategy. LEAN PRODUCTION SYSTEM STANDARDIZATION Flexible Motivated Employees ...maintain standards. ...kaizen (improve system). Foundational Stability through... Process of establishing the repeatability and predictability of Man, Material, Method & Machine in work which when properly maintained forms the basis from which improvement can be made. FOUNDATIONAL GOALS DESIRED OUTCOMES THE "PILLARS" OF THE SYSTEM Jidoka The ability to stop a process by man or machine in event of a problem Tools: Andon Fixed-Position Stop Line-Stop Cord Pokayoke Just in Time Having only what is needed, only when it's needed and only where it's needed Tools: Continuous Flow Heijunka Kanban Multi-skilled Staff Std In-Process Inv Takt Time JIDOKA: 1) Andon - a visual control mechanism that displays the current state of work (i.e. abnormal conditions, work instructions and job progress). 2) Fixed-Position Stop - the position on the assembly line where a repeating process is completed. It is at these positions that the line will stop should an abnormality not be corrected in time. 3) Line-Stop ("andon") Cord - a mechanism, usually a rope, that a worker may pull to signal the need for assistance and which will stop the line if it can not be resolved quickly. 4) Pokayoke - low cost, highly reliable devices that will stop processes in order to prevent the production of defective parts. JUST IN TIME: 1) Continuous Flow - deploying consecutive processes next to each to eliminate in-process inventory and increase production flexibility. 2) Heijunka - the leveling of volume and variety produced over time. (level production) 3) Kanban - A small card that provides instruction and request to produce or request goods. 4) Multi-Skilled Staff - workers are able to perform a greater variety of activities to increase flexibility and opportunity to improve continuous flow. 5) Pull System - the system in which following processes draw from preceding processes the required parts, when they are needed and in the exact amount needed. 6) Standard In-Process Inventory - identifying an appropriate level of inventory contained within the continuous flow system to achieve optimal effectiveness. 7) Takt Time - the time allotted for the completion of each process in the production system. TPS TOOLS Consensus & Nemawashi Genchi Genbutsu "Go See" Visual Control Plan / Do Check / Action (reflection) Root Cause Analysis STANDARDIZATION: 1) Nemawashi & Consensus Building - assuring success through good relationships and good communication 2) Genchi Genbutsu - going and seeing first-hand a situation rather than hearing second-hand 3) Visual Control - mechanisms that demonstrate visually condition and status 4) Plan / Do / Check / Action - the process of setting a target, performing an activity, evaluating the results and taking necessary countermeasure activity to issues before setting a new target and repeating the process. 5) Problem Solving (Root Cause) - identifying a problem and pinpointing it to a specific and addressable root cause which can be countermeasured to prevent the problem from occurring again. © Nigel Thurlow 2012

TPS Lean Production System

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For the Customer For the Employee For the Company

1) Work Satisfaction2) Job Security3) Consistent Income

1) Market Flexibility2) Profit (= Sales Price - Cost)

1) Highest Quality2) Lowest Cost3) Shortest Lead-time

"Customer 1st" "Respect for Humanity" "Elimination of Waste (Muda)"...by aiming for 100% creative effort...by providing development...by providing challenges...by mutual trust with management

...in Man, Material, Method or Machine

...in areas of over-producing, waiting, conveyance, processing, inventory, motion, correction

... is the principle of considering the need and desires of the customer when determining direction and strategy.

LEANPRODUCTION SYSTEM

STANDARDIZATION

Flexible Motivated Employees

...maintain standards.

...kaizen (improve system).

Foundational Stability through...

Process of establishing the repeatability and predictability of Man, Material, Method & Machine inwork which when properly maintained forms the basis from which improvement can be made.

FOUNDATIONAL

GOALS

DESIRED

OUTCOMES

THE "PILLARS"OF THE SYSTEM

Jidoka

The ability to stop a process by man or

machine in event of a problem

Tools:

Andon

Fixed-Position Stop

Line-Stop Cord

Pokayoke

Just in Time

Having only what is needed, only when it's needed and only where

it's needed

Tools:

Continuous Flow

Heijunka

Kanban

Multi-skilled Staff

Std In-Process Inv

Takt Time

JIDOKA:1) Andon - a visual control mechanism that displays the current state of work (i.e. abnormal conditions, work instructions and job progress).

2) Fixed-Position Stop - the position on the assembly line where a repeating process is completed. It is at these positions that the line will stop should an abnormality not be corrected in time.

3) Line-Stop ("andon") Cord - a mechanism, usually a rope, that a worker may pull to signal the need for assistance and which will stop the line if it can not be resolved quickly.

4) Pokayoke - low cost, highly reliable devices that will stop processes in order to prevent the production of defective parts.

JUST IN TIME:1) Continuous Flow - deploying consecutive processes next to each to eliminate in-process inventory and increase production flexibility.

2) Heijunka - the leveling of volume and variety produced over time. (level production)

3) Kanban - A small card that provides instruction and request to produce or request goods.

4) Multi-Skilled Staff - workers are able to perform a greater variety of activities to increase flexibility and opportunity to improve continuous flow.

5) Pull System - the system in which following processes draw from preceding processes the required parts, when they are needed and in the exact amount needed.

6) Standard In-Process Inventory - identifying an appropriate level of inventory contained within the continuous flow system to achieve optimal effectiveness.

7) Takt Time - the time allotted for the completion of each process in the production system.

TPS TOOLS

Consensus & Nemawashi

Genchi Genbutsu "Go See"

Visual Control

Plan / Do Check / Action

(reflection)

Root CauseAnalysis

STANDARDIZATION:1) Nemawashi & Consensus Building - assuring success through good relationships and good communication

2) Genchi Genbutsu - going and seeing first-hand a situation rather than hearing second-hand

3) Visual Control - mechanisms that demonstrate visually condition and status

4) Plan / Do / Check / Action - the process of setting a target, performing an activity, evaluating the results and taking necessary countermeasure activity to issues before setting a new target and repeating the process.

5) Problem Solving (Root Cause) - identifying a problem and pinpointing it to a specific and addressable root cause which can be countermeasured to prevent the problem from occurring again.