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Lean Six Sigma Methodology
http//www.tefen.com/industries.asp?pageInstanceId
150
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Attributes of Lean Producers - they

• use JIT to eliminate virtually all inventory
• build systems to help employees produce a perfect
  part every time
• reduce space requirements
• develop close relationships with suppliers
• educate suppliers
• eliminate all but value-added activities
• develop the workforce
• make jobs more challenging
• reduce the number of job classes and build worker
  flexibility

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Waste in Operations

• Overproduction
• Waiting time
• Transporting
• Non-value added processing
• Inventory
• Defects
• Underutilized talent

Fig. 15.1, p. 686
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Time Function Map
Receive product
Order Product
Customer
Process Order
Sales
Production control
Order
Wait
Order
Print
Plant A
Product
WIP
Wait
Wait
Wait
Warehouse
Product
WIP
Plant B
Extrude
Product
WIP
WIP
Transport
Move
Move
12 days
1 day
1 day
13 days
4 days
10 days
9 days
1 day
1 day
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Production Process Flow Diagram
Customer
Purchasing (order inks, paper, other supplies)
Customer sales representative take order
Vendors
Prepress Department (Prepare printing plates and
negatives)
Receiving
Accounting
Printing Department
Warehousing (ink, paper, etc.)
Gluing, binding, stapling, labeling
Collating Department
Information flow Material flow
Polywrap Department
Shipping
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5 WhysExample

• The Washington Monument is disintegrating.Why?
  Use of harsh chemicalsWhy? To clean pigeon
  poopWhy so many pigeons? They eat spiders and
  there are a lot of spiders at monumentWhy so
  many spiders? They eat gnats and lots of gnats at
  monumentWhy so many gnats? They are attracted to
  the light at dusk.Solution Turn on the lights
  at a later time.

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5 S Philosophy

• Seiri Sort
• Seiton Set in Order
• Seiso Shine
• Seiketsu Standardize
• Shitsuke Sustain

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Steps to Reduce Setup Time
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Small versus Large Lots
JIT produces same amount in same time if setup
times are lowered
JIT Small Lots
A
A
B
B
B
C
A
A
B
B
B
C
Time
Small lots also increase flexibility to meet
customer demands
Large-Lot Approach
C
A
A
A
A
B
B
B
B
B
B
C
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JIT Reduced Wasteat Hewlett-Packard
Waste Reduction ()
20
Setup Time
30
Scrap
Finished Goods Inventory
30
40
Space
50
Lead Time
Raw Material Inventory
50
Work-in-Process Inventory
82
0
20
40
60
80
100
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Visible Kanban (Control)
Production Move
Production
Move
1- Card Kanban
2-Card Kanban
Visible Kanban
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JIT Experiential Exercise
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Kaizen Continuous Improvement

• DMAIC
• Define
• Measure
• Analyze
• Improve
• Control

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Kaizen Continuous Improvement

• PDSA
• Plan
• Do
• Study
• Act