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Lean Tools & Approaches

Lean Tools & Approaches. EMBA 8355 Satish Nargundkar. Waste (“Muda”) Elimination. Types of Waste – TIM WOOD T ransportation I nventory M ovement W aiting O verproduction O ver -processing D efects Spaghetti Diagram

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Lean Tools & Approaches

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  1. Lean Tools & Approaches EMBA 8355 Satish Nargundkar

  2. Waste (“Muda”) Elimination Types of Waste – TIM WOOD T ransportation I nventory M ovement W aiting O verproduction O ver-processing D efects Spaghetti Diagram (Source: http://leanprogression.co.uk/lean-techniques/spaghetti-diagram) Youtube Video

  3. Smooth Flow: Takt Time, Cycle Time, Process Lead Time • Takt Time. • German “Takt” means Beat, as in the timing of music. It sets the rate at which the process should operate based on customer demand. Takt Time = Time Available/Customer Demand • Cycle Time • Time interval between finished goods (between one piece exiting the system and the next) • Cycle time also can refer to the time taken to complete each step in the process. • Process Lead Time (Throughput Time): • Time for one part to move through system. Six Sigma Academy Amsterdam Video

  4. Value Stream Mapping (VSM) Goal: To understand what is actually happening in the process. To help see problems clearly. Drawing the VSM Show process steps Note time taken for each step (Value Added Time) Note time between steps (Non Value Added Time) Sum both for the entire process Compute efficiency GEMBA: Walk the process! Take samples, note variations too. Ron Pereira, GEMBA Academy Blog

  5. VSM Templates Online https://goleansixsigma.com/value-stream-mapping/ https://www.lucidchart.com/pages/templates/value-stream-map There are many other online resources for VSMs.

  6. VSM Exercise Draw a value stream map Process: Laundry (one washer, one dryer) Four people waiting to start washing. Loading takes 3 minutes Washer takes 40 minutes. Transfer to dryer takes 3 minutes 6 loads waiting to dry Dryer takes 80 minutes Folding/hanging takes 10 minutes What is the Cycle Time? Process Lead Time?

  7. Kaizen One week process to implement Lean Source: http://jipsportsbj.info/kaizen-presentation-format/kaizen-presentation-format-0714-kaizen-event-process-powerpoint-presentation-slide-template-download/

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