Transcript
Week 1 Introduction Lean Manufacturing
Objectives
Appreciation of the historical context for lean thinkingAwareness of the contrast between “mass” and “lean”Ability to define customer value and 7 wastes with respect to application examples Describe the power of kaizen events
Agenda
Supply Chain ManagementHistory of LeanLean vs Traditional ThinkingWaste and ValueSand cone
Literature
What Is The Problem?
History of Lean
Why were Dutch-traders so successful?
History of Lean
Arsenal in Venice
Assembly line (T-Ford)
JIT at Toyota
Lean Manufacturing
Lean Thinking
Muda (Waste)
Muri (Overburden)
Mura (Oneveness)
1
2
3
“Lean Vs.Traditional”0 25 50 75 100
Productivity improvements
WIP Reduction
Quality improvements
Space savings
Lead time reduction
Assignment “Lean Vs.Traditional”
Buying
Business strategy
Sourcing
Supply chain
Sales price
Manufacturing
Planning
Quality
A Buy cheapest in the worldB. Buy to achieve lowest total costA. Economic of scaleB. Flexibility and adaptabilityA. Buy in country where manufacturing is performedB. Support with dual sourcingC. Minimize Number of SuppliersA. Keep supply chain short as possibleB. Supply chain is as strong as its weakest supplierA. Sales price = Cost + ProfitB. Profit = Sales price – CostA. One piece flowB. Batch and queueA. Mix of push and pullB. PushA. Inclusion (built-in by design and methods)B. Inspection after production
It is all about People ….
What is Lean?
•Philosophy•The endless pursuit of waste elimination•Delivers value to the customer, with little or no
unnecessary consumption of resources•Makes work more satisfying (because we spend more time on doing the “right things”).
•Can create more capacity by creating efficiency.
Lean focuses on value- as defined by the customer- by eliminating waste.
What is Value?
Three criteria:1. Transformation of goods or information2. The customer wants it
What, When, Where, How3. Do it right the first time
.
PRINCIPLES OF LEAN-7 WASTES
What are the WASTES of Lean?•Transportation•Inventory•Motion•Waiting•Overproduction•Overprocessing•Defects
PEOPLE
TYPESOF
WASTE
Processing
Motion
Waiting
FixingDefects
Making TooMuch
MovingThings
Inventory
What kind of Waste is displayed here?
Assignment
Observe the video about a grocery. What kinds of waste do you think are eliminated or reduced ?
Batch Processing vs One Piece Flow
Inventory Hides Problems
Poor Quality
UnreliableSupplier
MachineBreakdownInefficient
Layout
BadDesign
LengthySetups
Lower Levels Of Inventory To Expose Problems
Poor Quality
UnreliableSupplier
MachineBreakdownInefficient
Layout
BadDesign
LengthySetups
Sand Cone Model
Assignment
Paradigm Shift (see BB)
top related