Lean Overview

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Lean Overview

• Miramar Associates Inc.

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JUST IN TIME DEFINITION CONDITIONS

• DEF.- Produce only what is needed at the time the
  customer needs it.
• CONDITIONS
• 1- Production pace to TAKT time.
• 2- Pull System.
• 3- Leveled operations.
• 4- One Piece flow

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4 Week- Forecast
90 Day Forecast
Logistics
Melte Ltd
Weekly Fax
Daily Order
2000kg container
Weekly Schedule
6200 A 3400 B
2500 A 1450 B
1920 A 1080 B
1740 A 980 B
9600 A 5400 B
Ingots 11 days
Value Added Time 217 Sec.
15 Sec.
30 Sec
54 Sec.
100 Sec
18 Sec
11 Days
10,9 Days
2,0 Days
2,2 Days
2,9 Days
7,0 Days
Production Lead Time 36 Days
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In Action Going to GEMBA
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Waste found in process
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Current state value stream map
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IV. Value Stream Design Kaizen Vision
6 week- forecast
90 Day Forecast
Logistics
Melte Ltd
Dailly order
Daily Order
1000kg container
2 days
1 day
Value added time 136 sec.
Availability95
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Future State map
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Proposed Layout
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Cost/ Benefit analysis
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TAKT VS. CYCLE TIME CHART B-4 LEVELLED OPS.
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Time studying the setup of the 57 Cell
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TAKT VS. CYCLE TIME CHART-LEVELLED OPERATIONS
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3 Elements of standard work

• Standard
• The best, safest, easiest and effective way of
  performing a certain task, achieving the best
  link between human and machine work
• The 3 elements of Standard Work
• Takt Time
• Work Cycle
• WIP (Work In Process)

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Spaghetti Diagram of work flow in lab
Before Five S
After Five S
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Organizing Maintenance grinding supplies and work
area
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5S Improvements Needed
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10X12 Clamp Downtime Pareto
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Spaghetti Diagram Before
Distance 8742 ft
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Spaghetti Chart After
Distance 768 ft
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Make new setup method with prep,synchronizing
steps,
Cost- 0, Savings- 40 minutes
10X12 CLAMP Setup Instruction                                                            
Preparations for Setup(prior to setup)                                                            
Team Leader                                                            
Cleans mix plates of new mold X X                                                        
Get safety equipment     X                                                  
Retrieve large Hilo stages mold hilo       X X X                                                
To be done before last part is done                                                            
  5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150
After last part is trimed and loaded                                                            
Material handler                                                            
Moves out racks of parts X                                                          
Removes existing fixtures   X X                                                      
Add paint and switch lines       X X X                                                
Operator                                                            
Shuts off water opens drains X                                                          
Cleans up large debris on floor   X                                                        
Removes the water lines hydraulic lines     X X                                                    
Adjust clamp light         X                                                  
Tilt press back         X                                                  
Bring cage over, load trimmers and install           X                                            
Clean mix heads             X X                                          
Remove cage                 X                                      
Bring hilo in remove mold                   X X                                      
BrinG new mold in, clean install                     X X X X X                            
Remove hilo                                 X                          
Bring cage over, load trimmers and install                                   X X X                    
Remove cage                                         X                  
Tilt clamp down                                           X                
Tie the lines back                                             X X            
Turn on heater                                                 X          
Attach mix heads                                                   X X      
Set up process settings                                                       X    
Set clamp light                                                         X  
Bring paint up/ clean mold                                                           X
Shoot first part                                                            
                                                             
                                                             
10X12 CLAMP Setup Instruction                                                            
  5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150
Trimmer 1 2                                                            
Unbolt the heads X X                                                        
Remove steps     X                                                      
Unbolt the mold           X X X                                          
Bring hilo in to mold remove                   X X                                      
Bring new mold in, clean install                       X X X X X                            
Remove hilo                                 X                          
Bring cage in load trimmer and install                                   X X X                    
Hook up water hydraulic lines                                         X X            
Attach mix heads                                                 X X      
Bring steps in                                                       X    
Put fixtures in place                                                         X X
                                                             
                                                             
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Autonomous Maintenance Standards
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How to perform PM one point lesson
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Why take Lean beyond the shop floor?

• The amount of lost revenue as a result of poor
  service quality runs as high as 50 of the total
  costs associated with the delivery of those
  services. Professor S. Seshardi, Professor of
  Operations Management, NYU
• The biggest challenge is getting service
  employees to understand that they use processes.
  After 30 years of TQM and other improvement
  programs, people in manufacturing already have
  this perspective. They know what a process is,
  how to analyze it, and how to improve it. This is
  all new for people in service companies.
  Claude Brunet, Management-Board member
  responsible for Operations AXA (McKinsey
  Quarterly, May 2005)
• Over the past 3 decades, productivity as measured
  by output per person hour, nearly TRIPLED for
  manufacturing companies vs. 40 increase for
  service companies US Bureau of Labor
  Statistics, Booz Allen Hamilton
• Approximately 5- of activity in financial
  services companies is non value adding Lean
  Enterprise Resource Center

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Goals

• Redesign the current P2P process so that it is
  efficient, user-friendly and SOX compliant.
• Identify and eliminate waste
• Standardize work to avoid errors
• Improve office productivity
• Establish metrics

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Team

• Chuck Krasovic Controller
• Rowena Grospe Sr. Accountant
• Toni Smith A/P Specialist
• Katie McKenzie Admin Asst.
• Bruce Yeh Procurement Manager
• Kara Mingarelli Admin Asst.
• Mark Reid Warehouse Supervisor
• Tanya Vilcek Business Ops Manager
• Julie Rayle Consultant
• Brian Saylor - Consultant

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Action List for Waste Removal
Item Problem(What, How, Where, When) Causes(Why) Solution(Actions) Who When Status
1 Need to define when a purchase is taxable or not (TX, CA, MI). We dont have a good definition/understanding on when we need to pay sales tax on purchases 1. Define IRS rule on taxable.2. Add "purpose" field to PR with drop down options with examples3. Make sure taxable/non taxable field shows up on PO 1. Row to consult other sources2. Kara3. Julie 1. Before 12/222. First draft by 12/173. Before 12/31  
2 Verbal Request - Any request without proper paperwork (given verbally or via email) Non-compliance, laziness, lack of time Requestor completes PR for any purchase Sends to correct person Training on purchasing Add to New Employee Orientation Enforce! Kara (AUS) Katie (SD)Josh (HR) Paul/Nicole w/o 12/20  
3 Purchasing unaware of project budget PR process didn't specify distribution list of project budget recipients 1. Place project budget on a shared drive where the whole company can access2. Establish naming convention on project budget 1. IT2. Chuck / Tanya Before 12/31  
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P2P Future State VSM
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Office Area Being sorted and cleaned
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Future State VSM Summary

• Value Added Activities (VAT 7.8 hrs)
• Turnaround Time (TAT 23 hrs)
• Through Put Time (30.8 hrs)
• Waste 75
• Cost 273 per PO (assumption of 35/hr)
• Savings 48 per PO
• November 2010 savings 30,240

Current State VSM Summary Value Added Activities
(VAT 15 hrs) Turnaround Time (TAT 86.75
hrs) Through Put Time (102 hrs) Waste 85 Cost
525 per PO (assumption of 35/hr)
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• MAKE IT HAPPEN