Concepts in Lean Manufacturing

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Concepts in Lean Manufacturing

• Presented by Christy Thornton, Bill Tinsley,
  James LeMeilleur, Brian Huckaby

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PURPOSE

• This training module will introduce you to the
  concept of Lean Manufacturing

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Presentation Styles

• Lecture
• Audio Visual
• Self-Directed
• Team Building

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OBJECTIVES

• Introduction
• Divide into four groups
• Build cars and decide fate of excess inventory
• Discussion about lean processes
• Apply lean processes
• Evaluation

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What is Lean Manufacturing?

• It is an assembly-line manufacturing methodology
  developed originally for Toyota and the
  manufacture of automobiles. It is the optimal
  way of producing goods through the removal of
  waste and implementing flow

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What is the goal of Lean Manufacturing?

• "to get the right things to the right place at
  the right time, the first time, while minimizing
  waste and being open to change".

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ASSEMBLY

• Build car
• Decide to build second car
• Or send extra parts back

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ASSEMBLY

• Yellow Car

• Red Car

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DISCUSSION

• Lean Manufacturing is all about having the right
  part for the right job when then job is needed
• So, in the previous example the parts should have
  been sent back
• Assembly goal only add cost to the product when
  the order comes in for the product

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Ten Rules of Lean Production

• 1. Eliminate waste ?
• 2. Minimize inventory ?
• 3. Maximize flow ?
• 4. Pull production from customer demand ?
• 5. Meet customer requirements ?
•  

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Ten Rules of Lean Production

• 6. Do it right the first time ?
• 7. Empower workers ?
• 8. Design for rapid changeover ?
• 9. Partner with suppliers ?
• 10. Create a culture of continuous improvement
• ?
•  

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Total Quality Management

• Total Quality Management (TQM) movement cannot be
  separated from Lean Manufacturing
• Total Quality Management (TQM) is a comprehensive
  and structured approach to organizational
  management that seeks to improve the quality of
  products and services through ongoing refinements
  in response to continuous feedback.
• Plan, Do, Check, Act

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APPLICATION

• Start the assembly line again and follow it with
  the final person in charge quality control
• Only build to fill orders
• Maintain quality
• Continue to improve and streamline process

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ASSEMBLY

• Yellow Car

• Red Car

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EVALUATION

• Build time was reduced
• Customer needs were met
• Waste was eliminated
• Quality was improved
• Warehouse space was not needed or wasted for
  parts inventory or finished goods