Introduction to Lean

Presented toProfitability in Manufacturing MEP

By Bill Bearnson

What is Lean Manufacturing?

Identifying what the customer wants in form fit and function of a product. What the customer is willing to pay for. Anything else is waste.

Systemic removal of any activity that does not add value to the form fit or function. This is waste.

A systemic process to improving flow of a product focusing on what adds value and the customer will pay for.

What is Lean Manufacturing?

A commitment to manufacturing culture change.

• The most noteworthy accomplishments in keeping the price down low is the gradual shortening of production cycles. Henry Ford

• It encompasses the successful execution of all manufacturing activities required to produce a final product, from design engineering to delivery and including all stages of conversion from raw material onward. Dr. Shingo Shigeo

Common Wastes1. Transport (moving products that are not actually required to perform the

processing). Example: inspection stations instead of “in process inspections”.

2. Inventory (all components, work in process, and finished product not being processed). Example: Component failures not accounted for and reported in supplier rating.

3. Motion (people or equipment moving or walking more than is required to perform the processing). Example solution: equipment repair done in test lab.

4. Waiting (waiting for the next production step, interruptions of production during shift change). Example: Setup and tear down time due to parts missing or cross training.

5. Overproduction (production ahead of demand). Example: Fast food.

6. Over Processing (resulting from poor tool or product design creating activity). Example: Design for manufacturing is missed. Test till it passes.

7. Defects (the effort involved in inspecting for and fixing defects). Example: manufacturing assets being used for evaluating returned product revisions and failures

Some Lean Tools

• Five S, Kanban (pull systems)• Value Stream Mapping: Kaizan event• Redesigning working cells. Reducing

movement.• Continuing improvements. • single point scheduling. Master scheduler.

What is 5S?

The results you can expect from a Five S program are: improved profitability, efficiency, service and safety. A great place to start Lean effort

What’s a Kanban and will they hurt me?

Kanban aligns inventory levels with actual consumption.

Toyota optimized its engineering process by modeling it after supermarkets stock shelves. Or, Just in time.

Value Stream MapCentral Control.

Critical Design Review

Lean ToolsProcess Flow Diagram

Engineering Design Effort

Purchase long lead parts

Preliminary Design, PL and DWG Review

Design Released

Long lead parts identified for management review.

Release long lead P/L , preliminary

drawing and prelim full P/L

Parts being received hold rack

Cycled until full kit ready

MFG and Test/Eval & Processing per priorities

Manufacturing Processes document begun and complete

Parts and Processes dropped to manufacture floor for build and test.

Customer Requirements

Buy LLP Decision is a GO!!

Buy LLP Risk Decision is Yes

TEST , MFG and MFG MNGT

begines involvement

RISK

Flow diagramming Benefits1. Bring Team together 2. Team agrees on Risks and mitigation

actions3. Cross functional review early by all

stake holders. 4. Better use of manufacturing assets.

Summary

Lean is:A commitment to

manufacturing culture change.

Lean Return on Investment:1. Improved manufacturing

efficiency. 2. Quicker Delivery3. On target customer wants

and needs they will pay for.

4. Lower Cost Product.5. Company staff retention

and moral.

Support

Lean Engineering Tools

The product design is not just based on good design but it should be possible to produce by manufacturing as well.

1. Design for Manufacturability2. Robust Design with variation control

Lean Engineering Tools

Robust Design by variation control.

Robust parameter designs used to make visula the interaction between control and uncontrollable variables by robust design.

Once optimal control factors are implemented, it is ready for production and delivery.

Robust DesignExample: resistor pack reduction concept

Value RFresistors

Variable 10k-12kRP

Gain output dBm

Spec’d Circuit Gain

.5k 10-12k 20-24dB 3-4dB1k 10k-12k 7-10dB 3-4dB2k 10k-12k 5-6dB 3-4dB3k 10k-12k 3dB-4dB 3-4dB4k 10k-12k 2-3dB 3-4dB5k 10k-12k 2-2.4dB 3-4dB

10k 10k-12k .01-2dB 3-4dB

400 – 400KHz

Lean Engineering Tools

-- Design for manufacturing (DFM)1. Simplify parts list where possible.2. Specify parts for use, environment and possible

future environments.3. Record risks taken in prototype stage for addressing

in first time build.– Unavailable parts that will make the sell but don’t meet

specification completion.– Parts that may impede manufacturing and test flow. Note

the risk and known mitigation.4. Review for first time build and low rate build with

MFG, Design, build technicians, process and Test.