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What is Lean?

What is Lean?. Lean is a business system that focuses on doing only those things that add value to the customer, creating continuous one piece flow, and placing a high value on developing people at all levels of the organization.

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What is Lean?

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  1. What is Lean? Lean is a business system that focuses on doing only those things that add value to the customer, creating continuous one piece flow, and placing a high value on developing people at all levels of the organization. Brian Hatcher

  2. Improvement Methods Lean Manufacturing Lean Six Sigma Total Quality Management Agile Manufacturing Toyota Production System Six Sigma Theory of Constraints

  3. Principles of a Lean Operating System Eliminate Waste Increase Speed & Response Improve Quality Reduce Cost

  4. Waste - Muda Waste is anything that the customer is not willing to pay for. Necessary Waste - Customer does not want to pay for but is willing to pay for – does not add value to the product Un-necessary Waste – Does not transform the product – we want to get rid of this waste

  5. 7 Wastes in an Organization Transportation Inventory Motion Waiting Over-production Over-processing Defects T I M W O O D

  6. Lean Tools 5S Visual Controls SMED Small Batch Single Piece Flow Quality and Continuous Improvement Total Productive Maintenance Manufactured Good Recovery

  7. House of Lean

  8. 5 S • Sort - Seiri (Organization) • Set In Order – Seiton (Orderliness) • Shine – Seiso (Cleanliness) • Standardize – seiketsu (Standardized Cleanup) • Sustain - Shitsuke (Discipline)

  9. 5 Pillars of the Visual Workplace, Hirano, p. 20, 1995

  10. Visual Controls

  11. SMED – Quick Change (Single Minute Exchange of Die) • Pre – changeover • During changeover • Startup • After Startup Increases capacity by creating more available production time.

  12. Single Piece Flow Make small batches and changeover quickly or single piece flow from pone process to the next. Value Stream Thinking ( From dirt to shelf ) Takt Time = available production time per day customer demand per day This is the customer demand for your product or service… the pace at which you must produce.

  13. Value Stream Mapping Workshop, Rother and Shook, p. 71, 2002

  14. Value Stream Mapping Workshop, Rother and Shook, p. 72, 2002

  15. Quality Advanced Statistical Methods (TQM, Six Sigma) W. Edwards Deming, Motorola Zero Quality Control – Quality at the source (Poka Yoke) Shingeo Shingo

  16. Lean Six Sigma Define Measure Analyze Improve Control Design of Experimentation (DOE)

  17. Kiazen(Continuous Improvement) • Business Process Kiazen (Value Stream) • Kiazen Workshops (5S Event) • Daily Kiazen (Daily Improvement)

  18. The Deming (Shewhart) Cycle

  19. TPM (Total Productive Maintenance) • Participation of all employees (not just maintenance) • Identify problems before they are problems • Correct problems when down time can be planned • Decreases production variablilty

  20. Just in Time Systems Pull vs. Push Inventory Management (Supermarket – Kanban) Production Management (Level loading – Heijunka)

  21. Manufactured Good Recovery • Managing waste streams • Recycling

  22. Four Hour House

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