What is Lean ?
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Transcript of What is Lean ?
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LeanWhat is Lean?
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“A manufacturing philosophy that shortens the time line between the customer order and the shipment by eliminating waste” - John Shook
What is Lean ?
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What is Lean?
A strategy for maximizing value to customers
The relentless pursuit of the perfect process through waste elimination
A competitive advantage to produce:What is needed (customer expectations, quality, etc.)When it is neededUsing the absolute minimal resources
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8 Types of Waste
Muda
Defects
Overproduction
Waiting
Non-Utilized
Resources
Transportation
Inventory
Motion
Extra-processing
“DOWNTIME”
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Defective work or non-conforming output
Typical causes: Variation in processesLack of Standard Operating Procedures
Improvement ideas: Poke Yoke (Mistake Proofing) Jidoka (Autonomation) Cross training Document procedures Establish information needs
Waste - Defects
Manufacturing Example Service Example
Wrong packaging Wrong data entry
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Producing beyond what is in immediate use
Typical causes:Production schedules & push productionCost justification for expensive equipmentWorking on the wrong parts at the wrong time
Improvement ideas: Reduce lead time and order quantity Establish a kanban system Level out the orders Remove all unnecessary paperwork Improve quality
Waste - Over-productionManufacturing Example Service Example
Producing more due to big batch size.
Producing a weekly report daily
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Any delay between when one process steps ends and the next begins.
Typical causes: Idle time due to lack of “standard” operations Waiting for decisions (dispositions, inspections, materials, etc.) Waiting for shared equipment
Improvement ideas: Balance operations Eliminate unnecessary approvals Eliminate redundancies Establish Single piece flow Eliminate hand-offs
Waste - WaitingManufacturing Example Service Example
Downtime to machine changeover
Waiting for signatories prior to report submission
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Not utilizing resources to its full capacity
Typical causes: Lack of standards Idle time
Improvement ideas: Do a skills matrix Cross training Level out orders Balance operations
Waste – Non-Utilized ResourcesManufacturing Example Service Example
Senior engineer doing manual tasks
Senior lead processor manually correcting entries
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Needless movement of work, products or information
Typical causes: Unnecessary inventory Poor shop/office layout
Improvement ideas: Reduce inventory Reduce lead times Eliminate unnecessary files Create a paperless process Review record retention policy
Waste - TransportationManufacturing Example Service Example
Transfer of materials to another processing area
Shipping hard copies requiring signatures.
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Excess WIP vs what is needed by the customer
Typical causes: Push production Over-ordering Too many shelves Too much floor space
Improvement ideas: Reduce lead times Establish kanban system
Waste - InventoryManufacturing Example Service Example
Excessive buffer stocks Claimed forms in a workflow stuck in the mailbox
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Needless movement of people
Typical causes: Equipment/Office layout Fixture design Material storage
Improvement ideas: Implement point of use Develop work cells
downover
Waste - MotionManufacturing Example Service Example
Unnecessary twisting, bending and reaching movements of operator.
Opening 5 subdirectories to access a frequently-used file
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Doing more work than is necessary to satisfy your customers.
Typical causes: Work is not standardized Tasks are not simplified Operations are not understood
Improvement ideas: Automate the process Eliminate non-value added steps Combine steps/forms
Waste – Extra-ProcessingManufacturing Example Service Example
Transfer of materials to another processing area
Excessive approvals or handoffs
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Lean Principles5 principles of Lean
Define value from the end customer back Identify the value streamEstablish flowPull from the customerContinuously improve the process to perfection
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Thank you !