LEAN Manufacturing

1
LEAN Manufacturing

• Jason Prior

2
Introduction to Lean

• Overview of Lean in Toyota video.
• Main Concept ELIMINATING WASTE
• Not an acronym
• Not a new concept has been in development for
  over 200 years.
• Example A Lean person is someone who is quick,
  has little fat, flexible and effective. The same
  can be said for a Lean organization.

3
Value Stream

• Value Stream video
• Approximately 95 of a value stream is waste or
  non-value added time
• Value stream mapping visually maps the flow of
  materials and information through all processes
  until the product reaches the customer.
• Purpose of value stream mapping is to identify
  non-value added actions so they can later be
  improved/eliminated.

4
Value Stream Map- John Deere
5
Types of Waste or Muda

• Transportation
• Inventory
• Unused Creativity
• Waiting
• Overproduction
• Complexity
• Defects

6
Customer Pull and Kanban Systems

• A method of controlling the flow of production
  through the factory based on a customers demand
• Alternative to producing according to a forecast
• If you read this say I watch barney out loud now
• Implementation will reduce lead times, minimize
  work in process, optimize floor space usage,
  simplify production signals and improve on-time
  delivery to your customers.

7
Kanban Example

• Kanban mean visual record in Japanese
• An example

8
Just in Time

• Parts arrive through the supply chain shortly
  before they are needed for production
• Inventory Strategy that a business implements to
  reduce work in process (WIP).
• Must be coordinated with suppliers
• Saves Space

9
5S Organizing a Workplace

• Sort- red tagging anti-just in case attitude
• Set in Order- "A place for everything and
  everything in its place."
• Shine- Clean so malfunctions easier to spot
• Standardize- simplify the process so easy to
  repeat and sustain
• Sustain- never finished

10
5S
Sort
Set in Order
11
5S Shoe Factory Indonesia
Before
After
12
Continuous Improvement (Kaizen)

• Improvements should be made both radically and
  incrementally
• Radical improvements include overhauling a batch
  system into a flow system
• Incremental improvements focus on attacking waste
  in the value stream
• Vital to create a vision of the process and
  eliminate waste one step at a time to achieve the
  goal
• Compete against perfection as well as
  competitors.

13
Homework

• It is obvious that 5S is successful in
  manufacturing environments. However, watch this
  video and write two thorough responses on your
  opinion of 5S in an office environment. Choose
  two of the following topics
• Would you mind 5S-ing your desk space? Why or
  Why not?
• Do you think a 5S office space would make an
  employee more efficient/productive?
• Many people have their own organization methods.
  Would it be more effective to adopt 5S or allow
  employees free reign?
• http//online.wsj.com/article/SB122505999892670159
  .htmlvideo08C6384E-D821-4E06-8D3C-7127672621CFa
  rticleTabsvideo

14
The Lean Manufacturing Game
15
The Rules
16
Rules

• Divide into 2 equal teams
• There will be 8 available questions to choose
  from. The two teams will alternate choosing and
  answering questions.
• 1st question 100 2nd question200 3rd
  question 300 4th question 400
• If a team answers incorrectly the other team has
  the chance to steal the points
• Each team gets one Super Question which adds 200
  points to the questions value.

17
Put Away All Materials Now
18
The Questions

• Question 1
• Question 2
• Question 3
• Question 4

• Question 5
• Question 6
• Question 7
• Question 8

19
Question 1

• Name four types of waste in a Lean environment.
• Answer

20
Question 2

• The Toyota Production System was largely
  influenced by the Ford model. However, name an
  improvement made by Taiichi Ohno and the
  Japaneses that made the TPS much more effective.
• Answer

21
Question 3

• Briefly explain the concept of a pull system
• Answer

22
Question 4

• What is the overall concept of Lean in two words?
• Answer

23
Question 5

• Name the person accredited for perfecting
  interchangeable parts.
• Answer

24
Question 6

• What is the purpose of mapping a value stream?
• Answer

25
Question 7

• What is the definition of value added?
• Answer

26
Question 8

• Name all 5 Ss in order
• Answer

27
Answer Question 1

• Transportation
• Inventory
• Unused Creativity
• Waiting
• Overproduction
• Complexity
• Defects
• Main Questions

28
Answer Question 2

• JIT
• Working conditions
• Team development
• Cellular manufacturing
• Flexibility
• Kanban systems
• Quality circles
• Main Questions

29
Answer Question 3

• A method of controlling the flow of production
  through the factory based on a customers demand
• Main Questions

30
Answer Question 4

• Eliminate Waste
• Main Questions

31
Answer Question 5

• Eli Whitney
• Main Questions

32
Answer Question 6

• To identify non-value added actions so they can
  later be improved/eliminated.
• Main Questions

33
Answer Question 7

• Something the customer is willing to pay for.
• Main Questions

34
Answer Question 8

• Sort
• Set in Order
• Shine
• Standardize
• Sustain
• Main Questions