Workshop A Performance Boosting Tools

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Workshop A Performance Boosting Tools

• Reality Check Are you a Lean, Mean Manufacturing
  Machine ?

The Matrix Performance Measurement System
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Producing Profitability through Lean Manufacturing

• What is Lean Manufacturing ?
• Why should I adopt Lean Manufacturing ?
• How can I apply Lean Manufacturing ?

TPM
5s
Value-added
SU
Flow
Kaizan
Bus Info
Six Sigma
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What is Lean Manufacturing?

• A long-term philosophy to propel a box plant to
  higher profitability
• A business strategy that focuses on rapid
  continuous low-cost improvement in processes and
  productivity
• A tactical plan that integrates several tools
  into a complete package
• A relentless attack on waste using a set of tried
  and true tools and techniques

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Why adopt Lean Principals ?

• Increase capacity
• Reduce inventories
• Reduce Cycle Times / Lead times
• Lower space/facility requirements
• Lower overall costs
• Improve employee moral through increased
  involvement
• Increase sales through focus on customer and
  value-added activities

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Where did Lean Manufacturing come from?

• Lean Techniques are Not New
• James Womack Daniel Jones
• The Machine That Changed the World (1990)
• Lean Thinking (1996)
• Toyota Production System (1950s 1970s)
• JIT / Kanban / SU Reduction / SOP / 5s / Flow
• Motorola (1986-1988)
• Six Sigma / Variation Reduction / Process
  Capability

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Major Concepts

• Waste
• Seven types
• Overproduction
• Waiting
• Material Movement
• Excess Inventory
• Excess Motion
• Defects
• Unnecessary Processing / Converting
• Value
• Those things the customer wants and is willing to
  pay for.
• Value Stream
• All activities required to design, order, produce
  and deliver a product or service.

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Goal of Lean Manufacturing

• Focusing on the value stream, identify those
  things that create value vs. those that do not
  and relentlessly attacking waste.

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Major Tools

• Value Stream Analysis
• Identify Value-added vs. non-value added
  activities
• Six Kaizan Events
• 5s Housekeeping
• Flow
• Set-up reduction
• TPM
• Defect/Variation Reduction
• Business Processes/Information

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Value Stream Mapping

• Identifying Value Added vs. Non-value added
  Activities
• Product families items/orders with a common
  process or machine routing
• Target each product family for improvement efforts

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Kaizen Events

• Short burst of intense activity and effort (3-5
  days)
• Biased toward action over analysis
• Consist of multi-functional team assembled to
  achieve a specific goal or solve a specific
  problem
• Focused on improving the value stream and
  achieving flow
• Managed with daily reviews to resolution
• Goal driven Solving Problems and eliminating
  waste

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Kaizen Event 1

• 5s1 Housekeeping
• Sort
• Set in order
• Shine
• Standardize
• Sustain
• 1 Safety

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Kaizen Event 2

• Flow
• material, people and activities
• Macro Level and machine/dept level
• Lean Tools
• Spaghetti Diagram
• Flow Charts

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Kaizen Event 3

• Set-up Reduction
• Lean Tools
• Pit Stop Set-up mentality
• Video Tape and Set-up Analysis
• Internal vs. External SU activities

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Kaizen Event 4

• TPM Total Productive Maintenance
• Goal is to minimize downtime maintain
  capability of equipment
• Lean Tools
• Develop Daily Operator PM and Maintenance PM
• Develop equipment critical spare parts list
• 5s Program contributes toward TPM

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Kaizen Event 5

• Defect / Variation Reduction
• Six Sigma Tools
• Pareto Charts
• Histograms
• Process Mapping (KPIV, KPOV)
• Cause Effect Analysis
• FMEA
• Capability Analysis

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Kaizen Event 6

• Business Process / Information Flow
• Design Process
• Quotation
• Order Entry
• Manufacture Order
• Shipping Order
• Customer Feedback
• Accounting / Administration

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Keys to Successful Lean Manufacturing

• Education and Communication
• Employee Involvement empowerment
• Create a culture tolerant of experimentation -
  allow people to successfully make mistakes
• Break the paradigm that Inventory is an Asset
• Incorporate Lean concepts into you culture and
  ongoing strategic plan not a project

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Are you a Lean Mean Manufacturing Machine ?