Post on 05-Aug-2020
transcript
Introduction to LEAN
Workshop March 2nd, 2018
Ian Marshall – Lean Champion
Canadian Manufacturers & Exporters
Objectives
Ian Marshall – Canadian Manufacturers & Exporters
‘Introduce the terminology and philosophy of LEAN Thinking’ ‘Demonstrate the benefits of LEAN through simulation’
What is your level knowledge or experience of LEAN/Continuous Improvement: Beginner – limited knowledge Intermediate – some hands-on experience Advanced – number of years of experience
Introduction
Ian Marshall – Canadian Manufacturers & Exporters
Five Principles
of Lean Thinking
Customer Value - The only perception of Value that matters…
is the perception held by the customer
Value Stream - Map the Value Stream – keep it simple & involve
those who work the process… help them to see
Flow - Think flow – make everything flow without interruption…
stoppages collect cost, errors & waste
Pull - Let your Customer ‘Pull’ from you what they need when they need it
Perfection - pursue perfection… not competitors
Jim Womack - Lean Thinking
David Hogg – High Performance Solutions
Map the Value Stream
Process Steps
Cycle Times
Issues
Root Causes
Solutions
“Wherever there is a customer, there is always a value stream… your challenge is to see it.”
Jim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Information and Material Flow
Material
Information
Supplier Customer
Ian Marshall – Canadian Manufacturers & Exporters
How Lean Thinkers Think
More than 95% of total lead time
is usually Non-Value Adding time [Of remaining 5% ~ 2.5% is NVA but necessary ~ Hence 2.5 is VA]
Thinking Lean
begins by
focusing on
these spaces
Lead Time
-
Adding Cost
(Opportunity
or waste)
Adding Value
Red: Non-Value Adding time
(waiting, checking, moving, reworking etc.)
Green: Value Adding time
(designing, sourcing, installing, testing etc..)
Quote Cash
David Hogg – High Performance Solutions
The Classic Wastes
*Waste: That which adds cost with no value provided to the customer
For Service
Transport of Documents
Backlog of Work
Unnecessary Motion
Waiting for the Next Step
Doing Work Not Requested
Process Steps & Approvals
Errors in Documents
Not able to share talents…
Developed by Taiichi Ohno
David Hogg – High Performance Solutions
For Manufacturing
Transportation
Inventory
Movement
Waiting
Overproduction
Over Processing
Defects
Skills Underutilization
Product & Process Innovation, Inc.
Lean Definition
“Lean is an Operations’ Strategy
with a new set of Values to Engage
People in Continuously Improving
Safety, Morale, Quality, Cost and
Productivity.”
Jeffrey Liker, author of The Toyota Way
Lean Sensei International
The Toyota Way
Challenge Kaizen Respect Teamwork Go & See
Continuous
Improvement
The Toyota Way 2001
Respect
For
People
Lean Sensei International
The Toyota Way
“Everything we do is for the
purpose of showing us where the
problems are. We must constantly
identify problems, find their causes
and solve them in order to improve
for the long-term.”
David Meier, author of Toyota Culture
Lean Sensei International
Ian Marshall – Canadian Manufacturers & Exporters
Intro to Lean Tools
Video www.cme-mec.ca/mb
Ian Marshall – Canadian Manufacturers & Exporters
https://www.youtube.com/watch?v=OrHxPSyTTMk
The Machine That Changed The World – Womak, Jones & Roos
Lean Thinking – Womak
The Toyota Way – Liker
The High-Velocity Edge – Spear
Everything I Know About Lean I Learned in First Grade – Martichenko
Creating A Lean Culture – Mann
Leading The Lean Enterprise Transformation – Koenigsaeker
The Lean Turnaround – Byrne
Lean Office And Service Simplified - Locher
Managing To Learn – Shook
Understanding A3 Thinking – Sobek & Smalley
2 Second Lean - Akers
People (A leader’s day-to-day guide to building, managing and sustaining lean
organizations) – Gran, Martichenko, Miller & Pearce
Resources - books
Ian Marshall – Canadian Manufacturers & Exporters
www.cme-mec.ca
www.leansensei.com
www.lean.org
www.sme.org
www.ame.org
www.itc.mb.ca
www.TWI-Institute.com
www.superfactory.com
www.productivitypress.com
Resources - websites
David Chao – Lean Sensei International
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters