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Manufacturing Process Validation

Shop Floor Management. Open Communication Process. Shop Floor Management. People Involvement. People Involvement. Open Communication Process. Small Lot Packaging. Small Lot Packaging. Vision. Vision. Simple Process Flow. Simple Process Flow. Values. Fixed Period Ordering System/

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Manufacturing Process Validation

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  1. Shop FloorManagement OpenCommunicationProcess Shop FloorManagement PeopleInvolvement PeopleInvolvement OpenCommunicationProcess Small LotPackaging Small LotPackaging Vision Vision SimpleProcessFlow SimpleProcessFlow Values Fixed Period Ordering System/ Order Parts Fixed Period Ordering System/ Order Parts Values Qualified People Qualified People Team Concept Team Concept AndonConcept ControlledExternal Transportation AndonConcept ControlledExternal Transportation In-ProcessControl & Verification In-ProcessControl & Verification WASTE ProductQualityStandards ProductQualityStandards ManufacturingProcess Validation ManufacturingProcess Validation Total ProductiveMaintenance Total ProductiveMaintenance QualityFeedback/Feed- forward QualityFeedback/Feed- forward QualitySystemManagement QualitySystemManagement TemporaryMaterialStorage TemporaryMaterialStorage ScheduledShipping / Receiving Business Plan Deployment Business Plan Deployment ScheduledShipping / Receiving Managementby TAKT Time Managementby TAKT Time Early Mfg. and DesignIntegration (DFM / DFA) Early Mfg. and DesignIntegration (DFM / DFA) Internal Pull / Delivery Internal Pull / Delivery Level VehicleOrder Schedules Level VehicleOrder Schedules VisualManagement VisualManagement ContinuousImprovementProcess ContinuousImprovementProcess Work- placeOrganization Work- placeOrganization SupplyChain Management SupplyChain Management StandardizedWork StandardizedWork ProblemSolving ProblemSolving Health andSafety Priority Health andSafety Priority Lean Design of Facilities, Equipment,Tooling and Layout Lean Design of Facilities, Equipment,Tooling and Layout

  2. OUT OFORDER How Often Do We See These Scenarios in Our Work Area? Stocking Up Inventory Equipment Breakdown Excess Walking Decision -Communication and Reporting Maze Excessive Transporting,Storage & Handling Meetings, Meetings,Meetings!

  3. Definition of Waste • Anything that doesn’t add value to the product or service. • Anything that doesn’t help create conformance to the customer’s specifications. • Anything your customer would be unwilling to pay you to do. Non-Value Added Work Use Different Pict. Value Added Work

  4. Enemies of Any Process Three Enemies: 7 Wastes (Muda), Unevenness (Mura), and Overburden (Muri) Visual to be more understandable to Team members

  5. 7 TYPES OF WASTE CURRENT THINKING REQUIRED THINKING Shift Mindset Processing Correction P C Over Production Inventory O TYPES OFWASTE I WASTE W M M Motion Waiting Material Movement WASTE NOT DEFINED REACT TO LARGE EXAMPLES REACTIVE IMPROVEMENT WASTE IS "TANGIBLE" IDENTIFY MANY SMALL OPPORTUNITIES LEADS TO LARGE OVERALL CHANGE CONTINUOUS IMPROVEMENT Waste Elimination is the most Fundamental component of Lean Manufacturing

  6. Correction Elimination of Waste (cont’d) ØWaste of Correction: vWhen a job is not done correctly, extra time and money are used to repair defects. vThe extra cost of labor and materials is referred to as Waste of Correction. vAll repair activities are an opportunity to eliminate waste.

  7. Over Production Support by Practical Examples Elimination of Waste (cont’d) ØWaste of Over Production: vThis is the worst type of waste and leads to the other six types. v        The waste caused by producing more goods than are necessary or by producing goods at a rate faster than they are needed is called Waste of Over Production. v        This waste is a problem because it leads to extra cost for materials, transportation, warehousing, staffing, and energy. v        Working ahead on the assembly line only to wait later to work is another example of waste of Over Production.

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