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Lean PPT-4

Lean PPT-4.

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Lean PPT-4

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  1. Lean PPT-4 <a rel="license" href="http://creativecommons.org/licenses/by/4.0/"><img alt="Creative Commons License" style="border-width:0" src="https://i.creativecommons.org/l/by/4.0/88x31.png" /></a><br /><span xmlns:dct="http://purl.org/dc/terms/" property="dct:title">Lean PPT-4</span> by <span xmlns:cc="http://creativecommons.org/ns#" property="cc:attributionName">Dr.R.Gnanaguru</span> is licensed under a <a rel="license" href="http://creativecommons.org/licenses/by/4.0/">Creative Commons Attribution 4.0 International License</a>.

  2. Lean Manufacturing Dr.R.G. UNIT – IV : LEAN IMPLEMENTATION Training Stage-Management Commitment, Identify the value stream manager/Champion and core Implementation team Members, Training of team members, Planning stage-Customer Focus, Go to the floor, Hosin Planning, Brain storming, Prepare Tree Diagram, Select the cross functional team, Prepare project plan, Improvement stage-Production and Productivity-Operator, Process, Machinery and Equipment, Work place Organization, Inventory management, Planning and Procurement of Materials, A case study on Lean implementation in manufacturing and service industries.

  3. Lean Manufacturing Dr.R.G. TRAINING STAGE What is Training ? Why we need Training ? How to provide Training ? Whom to provide Training ?

  4. Lean Manufacturing Dr.R.G. TRAINING STAGE 1. Meeting with CEO / Directors 2. Brainstorm 3. Training in Lean manufacturing 4. Plant visit / detailed plant study 5. Training in process mapping

  5. Lean Manufacturing Dr.R.G. TRAINING STAGE 6. Project identification / discussion 7. Training in inventory management 8. Discuss sales / forecasting project 9. Training in Kaizen 10. Discuss project on inventory / purchase

  6. Lean Manufacturing Dr.R.G. TRAINING STAGE 11. Discuss production PLG project 12. Discuss QC project 13. Discuss production project 14. Meeting with CEO / Directors.

  7. Lean Manufacturing Dr.R.G. 4.2.MANAGEMENT COMMITMENT

  8. Lean Manufacturing Dr.R.G. TRAINING Top Management Champion Lean leaders Team members

  9. Lean Manufacturing Dr.R.G. IDENTIFY THE VALUE STREAM MANAGER/CHAMPION • Has visible leader • Develop the strategy training and implementation • Get financial approvals where required. • Plan and organize training programmes. • Plan cost saving monitor. • Keep the overall initiative on track.

  10. Lean Manufacturing Dr.R.G. • Inspire and promote lean culture. • Select the lean leaders and associates • Identify the projects and prepare a project . • Monitor the project on a regular basis and report to the top management. • Make sure the experience by the teams and shared. • Take full responsibility for the project.

  11. Lean Manufacturing Dr.R.G. The Lean leaders have the following responsibilities: • Prepare initial project assessment to validate benefits. • Lead and direct the team to execute projects. • Determine the most effective tools to apply. • Identify project resources. • Report progress to the lean champion. • Present the final report.

  12. Lean Manufacturing Dr.R.G. The Lean leaders have the following responsibilities: • Deliver results on time. • Solicit help from the champion when needed. • Teach and coach breakthrough methods and tools. • Manage project risk. • Calculate project savings. • Ensure the results are sustained. • Document the experience.

  13. Lean Manufacturing Dr.R.G. The responsibilities of Team members: Be part of the project team in carrying out lean projects Help in preparation of the project plan Participate in team meetings Assist the departments during project implementation Oversee progress and report to the lean leaders. Carry out tasks allocated by the leaders.

  14. Lean Manufacturing Dr.R.G. Objectives of the Lean training program are: To create an understanding of Lean theories and principles . To train and to identify roles and responsibilities of individuals responsible for implementing and sustaining specific Lean processes. 3. To develop a certification program of a Lean Practitioner.

  15. Lean Manufacturing Dr.R.G. Lean training activities should be divided into two main themes: Knowledge of Lean Tools and Methodologies. 2. How to Manage in a Lean Environment.

  16. Lean Manufacturing Dr.R.G. The three levels of Lean Training: Level I (Basic) – Principles of Lean Level II (Intermediate) – Activities Based Training Level III (Advanced) – Sustaining and Improving

  17. Lean Manufacturing Dr.R.G. LEVEL I (BASIC) – PRINCIPLES OF LEAN THEME: Knowledge of Lean Tools and Methodologies TRAINING MODULE-1.1.: PRINCIPLES OF JIT AND PULL SYSTEM TRAINING MODULE-1.2: ELIMINATION OF WASTE

  18. Lean Manufacturing Dr.R.G. LEVEL II TRAINING – ACTIVITIES BASED TRAINING THEME: HOW TO MANAGE IN A LEAN ENVIRONMENT TRAINING MODULE 2.1: 5S – WORKPLACE ORGANIZATION TRAINING MODULE 2.2.: JOB INSTRUCTIONS TRAINING MODULE2.3.: VALUE STREAM MAPPING TRAINING MODULE2.4.: INFORMATION CENTERS ABOUT PROCESS

  19. Lean Manufacturing Dr.R.G. THEME: KNOWLEDGE OF LEAN TOOLS AND METHODOLOGIES TRAINING MODULE 2.5.: VISUAL CONTROLS TRAINING MODULE 2.6. : TPM – TOTAL PRODUCTIVE MAINTENANCE TRAINING MODULE 2.7.: SET-UP TIME REDUCTION/QUICK CHANGEOVER TRAINING MODULE 2.8.: STANDARDIZED WORK

  20. Lean Manufacturing Dr.R.G. LEVEL III TRAINING – SUSTAINING AND IMPROVING THEME: HOW TO MANAGE IN A LEAN ENVIRONMENT TRAINING MODULE 3.1.: GEMBA KAIZEN – VISUAL MANAGEMENT THEME: KNOWLEDGE OF LEAN TOOLS AND METHODOLOGIES TRAINING MODULE3.3.: KAIZEN WORKSHOP – CREATING CONTINUOUS FLOW TRAINING MODULE 3.4.: PRODUCTION SCHEDULE –

  21. Lean Manufacturing Dr.R.G. 4.6. PLANNING STAGE

  22. Lean Manufacturing Dr.R.G. • The plan will have the following different levels. • Long term plan • Annual plan • Project plan • Detail plan

  23. Lean Manufacturing Dr.R.G. CUSTOMER FOCUS A customer’s basic requirements are: • On time Delivery, • good quality products and • low price.

  24. Lean Manufacturing Dr.R.G. HOSIN PLANNING

  25. Lean Manufacturing Dr.R.G.

  26. Lean Manufacturing Dr.R.G. 4.9. BRAIN STORMING Step by Step Guide 1. Review the rules of brainstorming with the entire group: No criticism, no discussion of ideas. There are no stupid ideas. The wilder the better. All ideas are recorded. Piggybacking is encouraged: combining, modifying, expanding others’ ideas.

  27. Lean Manufacturing Dr.R.G. 2. Review the topic or problem to be discussed. Often it is best phrased as a “why,” “how,” or “what” question. Make sure everyone understands the subject of the brainstorm. 3. Allow a minute or two of silence for everyone to think about the question.

  28. Lean Manufacturing Dr.R.G. 4. Invite people to call out their ideas. Record all ideas, in words as close as possible to those used by the contributor. No discussion or evaluation of any kind is permitted. 5. Continue to generate and record ideas until several minutes’ silence produces no more

  29. Lean Manufacturing Dr.R.G. 4.10. PREPARE TREE DIAGRAM

  30. Lean Manufacturing Dr.R.G. SELECT THE CROSS FUNCTIONAL TEAM

  31. Lean Manufacturing Dr.R.G. 4.12.PREPARE PROJECT PLAN

  32. Lean Manufacturing Dr.R.G. The following activities to be involved in the preparation of Project plan: 1. Brainstorming at all levels 2. Prepare project charter 3. Prepare detailed plan 4. Brainstorm the detail plan and finalize 5. Project control 6. Champion review 7. Review by the CEO.

  33. Lean Manufacturing 4.13. PRODUCTION AND PRODUCTIVITY Dr.R.G.

  34. Lean Manufacturing Dr.R.G. 4.14. OPERATOR • The operator efficiency variation can due to • Insufficient training; • Attitude of the operator; • Wastes in movement of the operator • while loading and unloading; • Searching for tools, materials and instructions; and • Fatigue due to environment.

  35. Lean Manufacturing Dr.R.G. 4.15. PROCESS Reduce cycle time Reduce Setup time Reduce movement of materials The cycle time can be reduced as follows: 1. Process map the existing process 2. Identify non-value adding process 3. Eliminate non-value adding process 4. Prepare modified process 5. Reduce the cycle time

  36. Lean Manufacturing Dr.R.G. 4.16. MACHINERY AND EQUIPMENT i. Eliminate Downtime. ii. Eliminate Rework / Rejection iii. Balance the line. iv. Improve Process Capability

  37. Lean Manufacturing Dr.R.G. Eliminate Downtime: • To non-availability of materials; • Machine breakdown; • Moving equipment defective; • Power failure; • Absenteeism; • Tool defective; • Quality problem; and • Setting change.

  38. Lean Manufacturing Dr.R.G. ii. Eliminate Rework / Rejection

  39. Lean Manufacturing Dr.R.G. iii. Balance the line: • Study the existing process. • Analysethe possibility whether one operator can work on all five machine. • Minimize work in progress. • Balance the work load among machines • Employ optimum labour • Optimization the process • Eliminate the waiting time.

  40. Lean Manufacturing Dr.R.G. 4.17. WORK PLACE ORGANIZATION • Improve workplace • Introduce single piece flow 4.18. INVENTORY MANAGEMENT • Raw material inventory • Work –in – process • Finished goods

  41. Lean Manufacturing Dr.R.G. 4.19. MATERIAL PLANNING • On time availability of material • Optimum inventory • Optimum storage space • Sales forecasts; • Previous months’ actual material consumptions; • Current stocks; • Long term agreements; and • Advance input from sales staff / customer.

  42. Lean Manufacturing Dr.R.G. 4.20. PROCUREMENT OF MATERIALS i. Capability ii. Availability iii. Pricing iv. Quality v. Stability

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