Lean 101 Lego Lean Orientation Lean Overview – The Basics…… Presented By: Bill Stockstill – TMAC Panel Members Rosina Wittmeyer – DRS Infrared Technologies, LP Bob Brunett – Bell Helicopter Textron Mike Navaira – Lockheed Martin Aeronautics
Jan 26, 2015
Lean 101 LegoLean Orientation
Lean Overview –The Basics……Presented By: Bill Stockstill – TMAC
Panel MembersRosina Wittmeyer – DRS Infrared Technologies, LP
Bob Brunett – Bell Helicopter TextronMike Navaira – Lockheed Martin Aeronautics
Lean 101 LegoLean Orientation
• Texas Manufacturing Assistance Center
• Our Mission:
– Improve the global competitiveness of Texas’ Manufacturers by applying the appropriate techniques and technologies.
• TMAC is part of the MEP System
TMAC works closely with Manufacturing Supply Chain to make them more competitive by providing assistance in appropriate use
of technologies and techniques
What is TMAC?
Lean 101 LegoLean Orientation
TMAC Services
• Management Controls, Systems, and Compliance– Planning & Policy Deployment– Financial Controls and Measurement Systems– EPA, OSHA– QMS, EMS, SMS
• Culture and Workforce Development– Supervisor and Technical Training– Teams/Team Facilitation
• Waste and Variation Reduction– Lean and Six Sigma– TPM– EHS– Facility Design and Relocation
• Technology Application– ERP, MRP– Automation & Mechanization
Lean 101 LegoLean Orientation
Cycle Time
“One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost.”
Henry Ford, 1926
Lean 101 LegoLean Orientation
Mass Production
Value-Added Time : MinutesTime in Plant : Weeks
ReceivingWarehouse
Kitting
Springs Diodes
Storage
Repair
Testing
ShippingWarehouse
Ship
Material
ORDER CASH
LEDs
Lean 101 LegoLean Orientation
Defining Lean
“A systematic approach to identifying and eliminating
waste (non-value-added activities) through continuous
improvement by flowing the product at the pull of the
customer in pursuit of perfection.”
The MEP Lean Network
Lean has been defined in many different ways.
Lean 101 LegoLean Orientation
Definition of Value Added
Value Added
Any activity that increases the market form or function of the product or service. (These are things the customer is willing to pay for.)
Non-Value Added
Any activity that does not add market form or function or is not necessary. (These activities should be eliminated, simplified, reduced, or integrated.)
Lean 101 LegoLean Orientation
Lean = Eliminating the Wastes
Value Added
Typically 95% of all lead time is non-value added
• Defects
• Overproduction
• Waiting / Busy Work
• Non Value Added Processing
• Transportation / Conveyance
• Inventory
• Motion
• Employees Underutilized
Non-Value Added
Lean 101 LegoLean Orientation
Benefits of Lean
Lead Time Reduction
0 25 50 75100
Percentage of Benefits Achieved
Productivity Increase
WIP Reduction
Quality Improvement
Space Utilization
Lean 101 LegoLean Orientation
Lean Strategic Initiative Elements
• Burning Platform – Operational Excellence as Key Strategy• Defined Roles and Responsibilities
– Management Sponsored and Driven– Mid-Management Fueled– Grass Roots Implemented
• Wide Spread Orientation• Formal Launch
– Need for Change– WIFM– Management Expectations – Layoff Policies
• Requires Management System– Regular Progress Checks– Communication– Integrated Measurements– Recognition and Rewards– Project Management
• Team Culture• Proposal System
Strategic Planning
Lean 6 sigma
ResourceAccounting
WorkForceDevelp
Lean 101 LegoLean Orientation
For More Information...
Mark Sessumes (817)312-5853email: [email protected]
Bill Stockstill (817)917-2564email: [email protected]