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Lean Manufacturing

Lean Manufacturing. Chapter 15 pp. 438-466 June 29, 2012. Lean Manufacturing. Definition Elimination Waste Continuous improvement 3 pronged approach “Relentless” focus on quality Eliminate waste Involve employees. Lean Manufacturing.

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Lean Manufacturing

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  1. Lean Manufacturing Chapter 15 pp. 438-466 June 29, 2012

  2. Lean Manufacturing • Definition • Elimination • Waste • Continuous improvement • 3 pronged approach • “Relentless” focus on quality • Eliminate waste • Involve employees

  3. Lean Manufacturing • “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.”

  4. Lean Manufacturing • Key principles • Value • Value stream • “mapping” • Flow • Pull • Perfection • culture

  5. Lean Manufacturing • Benefits • Lead time reduction • WIP reduction

  6. 45 minutes 14 days 1 day 60 minutes 30 minutes 2 days 1 day

  7. Lean Manufacturing • Benefits • Lead time reduction • WIP reduction • Quality improvement • Space utilization • Greater customer satisfaction

  8. “A systematic approach to identifying and eliminating….” • Value stream mapping

  9. “A systematic approach to identifying and eliminating….” • Value stream mapping

  10. “…waste (non-value added activities) …” • 8 wastes of lean • Overproduction • Inventory • Waiting • Defects • Extra processing • Excessive motion • Transportation • Underutilized employees

  11. “…waste (non-value added activities) …” • 8 wastes of lean • Overproduction • Inventory • Transportation • Excessive motion • Extra processing • Defects • Waiting • Underutilized talents

  12. “non-value added activities” • Value-added activities • Transforms or shapes material or information • Customer wants it • Done right the first time • Machining • Assembly • Painting • Sewing

  13. “non-value added activities” • Non-value added activities • Consume resources but create no value for customers • Could be stopped and it would be invisible to the customer

  14. “…through continuous improvement…” • kaizen • Satisfying the customer • People = most important resource • Quality at the source

  15. “…through continuous improvement…” • 5S’s • Sort • Stabilize (set in order) • Shine • Standardize • Sustain

  16. (Stabilize)

  17. Stability

  18. Stability

  19. Stability

  20. Stability • Traditional layout • Cellular layout

  21. 1 2 3 4 5 Lathe Drill Mill Mill Inspect 27 Seconds 27 Seconds 6 27 Seconds Drill 10 9 8 7 Pack Inspect Drill Test Stability

  22. (Stabilize)

  23. “…by flowing the product at the pull of the customer…” • Just-in time • Pull system (vs push) • Quick changeover (Set-up Reduction)

  24. “…by flowing the product at the pull of the customer…” • Pull system • Production based on actual consumption • Small lots • Low inventories • Management by sight • Better communication

  25. Pull System • Kanban

  26. Pull System • Kanban • Supermarket

  27. Quick Changeover (Set-up Reduction) Single minute exchange of dies (SMED)

  28. Quality at the Source • Source inspection • Means to inspect • Samples or established standards • Process documentation • Mistake proofing

  29. Quality at the Source • Source inspection • Means • Samples or established standards • Process documentation • Mistake proofing • Andon

  30. Standardization • Standardized work

  31. Involvement • Teams • with rotation of highly specified jobs • Cross trained/multi-skilled employees • can work many operations within a cell and operations in different cells

  32. 1 2 3 4 5 Lathe Drill Mill Mill Inspect 27 Seconds 27 Seconds 6 27 Seconds Drill 10 9 8 7 Pack Inspect Drill Test Stability

  33. Involvement • Teams • with rotation of highly specified jobs • Cross trained/multi-skilled employees • can work many operations within a cell and operations in different cells • Continuous improvement philosophy • Process quality, not inspection • Use of participatory decision making

  34. Why do it? • Reduced inventory • Improved quality • Lower costs • Shorter lead time • Increased productivity • Greater flexibility • Greater customer satisfaction

  35. Last comment • Lean and Six Sigma • “hand and glove”

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