A Brief Introduction to Lean

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A Brief Introduction to Lean
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Constraints on performance improvement

• Lack of funds, resources, time and personnel are
  the top four constraints that companies
  experience in achieving measurable improvements
  in business performance.
• Lack of Funds 43
• Limited Resources 42
• Lack of Time 40
• Lack of Qualified Personnel 32

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WHAT IS LEAN ?

• Lean is a systematic approach of eliminating
  waste so every step adds value for the Customer

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Definition

• Value - A capability provided to a customer at
  the right time at an appropriate price, as
  defined by the customer.
• Cost
• Quality
• Delivery

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What is Waste?
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Thinking Lean (5 Principles)

• Specify value
• can only be defined by the ultimate customer
• Identify the value stream
• exposes the enormous amounts of waste
• Create flow
• reduce batch size and WIP
• Let the customer pull product through the value
  stream
• make only what the customer has ordered
• Seek perfection
• continuously improve quality and eliminate waste
• From Lean Thinking by Womack and Jones

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The Seven Forms of Waste
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Overproduction Producing more/sooner than the
Internal or External customer needs.
"What do you mean the design's been changed!"
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Waiting Long periods of inactivity for people,
information, machinery or materials.
The parts were supposed to be here yesterday!"
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Waiting Long periods of inactivity for people,
information, machinery or materials.
Im the only one here on time
Courtesy of Vansco Electronics Ltd.
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Transportation Excessive movement of people,
information or materials.
I had to go across the street!"
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Inappropriate Processing Using the wrong set of
tools, procedures or systems.
Bigger is not necessarily better!"
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Inappropriate Processing Using the wrong set of
tools, procedures or systems.
We have to talk about the length of your emails
Courtesy of Vansco Electronics Ltd.
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Unnecessary Inventory Excessive storage and delay
of information or products.
Were running out of room. We need to expand!"
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Unnecessary Motion Any motion that does not add
value to the product or process.
Theres got to be an easier way!"
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Defects Frequent errors in paperwork, product
quality problems etc..
Of course its taking a long time!"
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Defects Frequent errors in paperwork, product
quality problems etc..
"I thought I ordered two dozen pens, not hens!"
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Seven Forms of Waste

• Overproduction
• Waiting
• Transportation
• Inappropriate Processing
• Unnecessary Inventory
• Unnecessary Motion
• Defects
• NOT USING THE CREATIVITY OF YOUR EMPLOYEES

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The 5 Principles of Lean Thinking

• Define value from the customer perspective
• Identify the value stream
• Make the process flow
• Pull from the customer
• Head toward perfection

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Lean Tools

• 5S
• Cellular Design
• TaktTime
• Heijunka(Load Leveling)
• Jidoka(Built-In Quality)
• Just-In-Time
• Kaizen (Continuous Improvement)
• Kanban
• OEE
• Line Balancing

• Poka-Yoke
• Standardized Work
• Waste Elimination
• Value Stream Mapping
• Spaghetti Diagrams
• Visual Factory
• Value Add Analysis
• Plan For Every Part
• Material Management
• Work-In-Process (WIP)
• 5Y