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© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com 1

Introduction to LeanManuacturin!




"ne Pa!e "verview

# $%e &ur&ose o 'ean is to

remove all forms of waste

from the value stream.

# (aste inc'udes cyc'e time,

'a)or, materia's, and ener!y.

# $%e c%ie o)stac'e is t%e

act t%at waste oten %ides

in &'ain si!%t, or is )ui't into

activities.



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com *

Contents

# +eneits o Lean Manuacturin!

# $%e "ri!ins o Lean

Manuacturin!

# (%at Is Lean Manuacturin!

# (aste, riction, or Muda

# Lean Manuacturin! and reen

Manuacturin!/ IS" 1001

# Some Lean Manuacturin!

$ec%niues

# Conc'usion



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com

+eneits o Lean

Manuacturin!

# Lean manuacturin!

de'ivers an insurmountable

competitive advantage over com&etitors w%o dont

use it eective'y.




+eneits o Lean

Manuacturin!415 Lower &roduction cost

%i!%er &roits and wa!es

# Cost avoidance 'ows direct'y tot%e )ottom 'ine.

425 Su&&orts IS" 1001 and

6!reen6 manuacturin!# 7eduction o materia' waste

and associated dis&osa' costs

%i!%er &roits

4*5 S%orter cyc'e times8 make-to-order vs. make-to-stock



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com

+ottom Line and t%e

Lan!ua!e o Money# $%e irst com&re%ensive

im&'ementation o 'ean

manuacturin! yie'ded8# Stock a&&reciation o * &ercent

&er year, or 1 years 4not

countin! dividends5

# :.2 &ercent annua' wa!e !rowt%

# $%e ne;t section wi'' discuss

'ean manuacturin!s ori!ins.



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com :

$%e "ri!in o LeanManuacturin!

<iscussion uestion8

(%o created t%e $oyota

Production System



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com =

"ri!in o t%e $oyota

Production System# $aiic%i "%no said o&en'y t%at

%e !ot t%e idea rom >enry

ords )ooks and t%e ?mericansu&ermarket.

# ords My Life and Work 419225

descri)es @ust-in-time 4AI$5 and

ot%er 'ean conce&ts e;&'icit'y.

# <e&'etion o su&ermarket s%e'

stock tri!!ers re&'enis%mentB it is

a 6&u''6 system 'ike kan)an or

<rum-+uer-7o&e.




+ottom Line 7esu'ts o

t%e $PS# $%e ord Motor Com&anys

ori!ina' stock !rew * &er

year 4not countin! dividends5and :.2 annua' wa!e !rowt%.

# $oyota recent'y su&erseded

enera' Motors as t%e wor'ds'ar!est automo)i'e com&any.

# $%e ne;t section wi'' s%ow %ow

t%e $PS de'ivers t%ese resu'ts.




(%at is LeanManuacturin!

? systematic approach tothe identification andelimination all forms of

waste rom t%e va'uestream.




Conce&t o riction,(aste, or Muda

Dnderstandin! o riction,waste, or muda is t%e

oundation o t%e 'ean

Manuacturin!.




$%e irst Ste& is to

7eco!niEe t%e (aste# $%is &rinci&'e %as )een

stressed )y8

# >enry ord

# $aiic%i "%no 4$oyota

&roduction system5

# $om Peters 4Thriving On

Chaos5

# S%i!eo S%in!o

# A. . >a'&in 4Zero Defects5



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com 1*

(aste "ten >ides in

P'ain Fiew# (e cannot e'iminate t%e waste

o materia', 'a)or, or ot%er

resources unti' we reco!niEe itas waste.

# ? @o) can consist o :3 &ercent

waste 4or even more5.

# C'assic e;am&'e8 )rick 'ayin!

in t%e 'ate 19t% century




Post-i')ret% +rick

Layin!

$%e so'ution is o)vious 4in

retros&ect5, )ut irst we %ave to

know t%at we %ave a &ro)'emG




Lessons so ar

# Waste often hides in plain

view.

# Peo&'e )ecome used to 6'ivin!

wit% it6 or 6workin! around it.6

# <einition or em&'oyees at a''

'eve's8 If it's frustrating, a

chronic annoyance, or a

chronic inefficiency, it's

friction. 4Levinson and

$um)e'ty, 199:, !C "ssentials

and !roductivity #mprovement ,

?SH Hua'ity Press5



© 2009, Levinson Productivity Systems, P.C.www.ct-yankee.com 1:

$PS <einitions o

(aste1. "ver&roduction

2. (aitin!, inc'udin! time in ueue

*. $rans&ortation 4)etweenworkstations, or )etween su&&'ier

and customer5

. on-va'ue-addin! activities

3. Inventory

. (aste motion

:. Cost o &oor ua'ity8 scra&,

rework, and ins&ection



© 2009 Levinson Productivity Systems P Cct ankee com 1=

(aitin! as a orm o

(aste# " t%e tota' cyc'e time or

'ead time, %ow muc%

invo'ves va'ue-addin!work

# >ow muc% consists o

waitin!

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