29 Introduction to Lean Manufacturing

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 1/12

©ABSLPowerSolutions2007©STMQualityLimited

STM QualityLimited

Introduction toLean Manufacturing

TOTAL QUALITY MANAGEMENT

Lean Manufacturing

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 2/12

©STMQualityLimited

STM QualityLimitedefinition of Lean Manufacturing

“Theproductionofgoodsusinglessof

everythingbyreducing„waste‟andincreasing

valueaddedactivity”

If it doesn‟t add value, it adds cost! 

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 3/12

©STMQualityLimited

STM QualityLimitedreparing for Lean Manufacturing

FiveLeanPrinciples 

Specify ValueIdentifywhatthe

customeractuallywants

•Wouldyoupayfor

somethingyoudidn‟t

want?

•Ifit‟snotaddingvalue,it‟saddingcost!

Identify the

Value Stream

Identifythewholeprocess

(mapping)•Whatarethefactsabout

ourprocesscapability?

•What„waste‟istherein

theprocess?Make product

flow

•Eliminatebottlenecksor

managethembetter

•Reduceoravoid„batch&

queue‟

•Getthemaintenanceright

Let the

customer pull Onlymakewhatthecustomerrequires,when

thecustomerwantsit.

ContinuousImprovement

Increasingpersonal&

companyknowledgeto

pursuethecomplete

eliminationofwaste.

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 4/12

©STMQualityLimited

STM QualityLimitedreparing for Lean Manufacturing

Reduction&eliminationof„waste‟elementsintheprocess

Equipmentreliability – PlannedPreventativeMaintenance(P.P.M.)

 AutonomousMaintenance&ConditionMonitoring

Continuousflow-onepartatatime(JIT)&pull„Kanban‟systems

Inventory(WIP)reductionthroughouttheprocess

Defectreduction-rightfirsttime,errorproofing&training

Visualmanagement – simplemeasures(KPI‟s)&drumbeat

Quickmachinechangeovers(SMED)

Teamwork&communication

Pointofusestoragebutnot„nests‟

Bottleneckmanagement

Sowhatdoes„best‟looklike?

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 5/12

©STMQualityLimited

STM QualityLimitedreparing for Lean Manufacturing

Disorganised

Organised

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 6/12

©STMQualityLimited

STM QualityLimitedrocess Mapping

 Aprocessis…

 Asetofactivitieswhichconvertinputstooutputsto

meetagreedcustomerrequirements.

“Drawaflowchartofwhatyoudo.Untilyoudo,youdo

notfullyunderstandwhatyouaredoing,youjusthave

ajob”

DrW.E.Deming

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 7/12©STMQualityLimited

STM QualityLimitedrocess Mapping

Characteristicsofanidealprocess…

 –  Eachstepaddsvalue

 –  Eachstepiscarriedoutonlyonce

 –  Stepsarecarriedoutinthebestsequence

 –  Usestheoptimumlevelofresource

 –  Meetscustomerneedsconsistently

 –  Minimumspacerequirements

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 8/12©STMQualityLimited

STM QualityLimitedhy Process Map?

Biggesttoolinlean – allothersaredeployedfrommapping

output

Bigpicture – detailcomeslater

Establishesrealprioritiesbythosewhodothework – action

planswithnames&dates

Dramaticshort&medium-termresults

Ideageneration&teaminvolvementindecisionmaking

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 9/12©STMQualityLimited

STM QualityLimitedrocess Atlas

Customerneeds CORE PROCESSES SatisfiedCustomer

KPI’s 

MANAGEMENT PROCESSES

STRATEGY

DATA

SUPPORT PROCESSES

RESOURCES

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 10/12©STMQualityLimited

STM QualityLimitedoundaries and Scope

Starttofinish…orderenquirytoreceiptofpaymentortighter

definitionwecaninfluence?

 Allpossibleproductsor„runners‟only?Thinkflow&volume

Whatfunctionsdoweneedinvolvedbeyondthisroomboth

internal&external?

Isthereanobviousneedformoreinformationatthisstage?

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 11/12©STMQualityLimited

STM QualityLimitedean Wastes

The„8LeanWastes‟(7+1)

Introductionto„TIMWOODS‟

7/29/2019 29 Introduction to Lean Manufacturing

http://slidepdf.com/reader/full/29-introduction-to-lean-manufacturing 12/12©STMQualityLimited

STM QualityLimitedIM WOODS

T  –  Transport

I  –  Inventory

M  –  Movement

W  –  Waiting

O  –  Over-processing

O  –  Over-production

D - Defects

S - Skill