Lean manufacturing

Sample

Lean Foundation (6 of 13)

Lean: 4P Model

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Lean can demonstrate how managers can dramatically improve their business processes by:– Eliminating wasted time and

resources.– Building quality into workplace

systems.



– Finding low-cost, but reliable alternatives to expensive new technology.

– Perfecting business processes.– Building a learning culture for

continuous improvement.


Eliminating Waste


Eliminating Waste (Muda)(1 of 13)

The first step in identifying waste is to identify those processes or procedures that add value.– This is accomplished by creating a

value stream map that shows every step in a process with details as to how the step is accomplished and the time it takes to accomplish the step.


Eliminating Waste (Muda)(7 of 13)

To help in finding waste, we want to map the value stream.– It is best to walk the actual path to get

the full effect.– Draw this path on the layout, and

calculate the time and distance traveled.

– This resulting drawing is called a spaghetti diagram.


The Lean House


The Lean House (2 of 6)

Then there are two outer pillars:– Just-in-time—probably the most visible

and highly publicized characteristic of Lean and TPS.

– Jidoka—the ability to stop the production line by man or machine in the event of problems.• Jidoka ensures that a defective part or

product never passes through the production line to the next station.


The Lean House (3 of 6)

The house also has foundational elements like standardized, stable processes, and heijunka (leveling out the production schedule).

Each element house is important, but more so is the synergy created by all the elements together.

At the foundation of the house there is stability.


14 Principles of Lean


14 Principles of Lean Long Term Philosophy (1 of 5)

Principle 1: Base your management decisions on a long-term philosophy, even at the expense of short-term financial goals.

– Do the right thing for the customer.– Strive to build trust with your

employees.


14 Principles of LeanThe Right Process will Produce the Right Results (1 of 10)

Principle 2: Create continuous process flow to bring problems to the surface.

– Redesign work processes to achieve high value-added, continuous flow.

– Strive to eliminate the amount of time that any work project is sitting idle or waiting for someone to work on it.



– Most business processes are 90% waste and 10% value-added work. • Strive to eliminate the waste from

every process. Begin by eliminating the mass production mindset of batch & queue.

– Takt time is the heart beat of one-piece-flow. • Takt is a German word for rhythm or

meter; it is the rate of customer demand—the rate at which the customer is buying product.



This is an example of a metal machining process before and after one-piece-flow was implemented.


Before After

14 Principles of Lean Add Value to the Organization by Developing Leaders from Within (1 of 9)

Principle 9: Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.

– Grow leaders from within instead of buying them from outside the organization.



– Lean leaders:• Understand the work• Have the ability to develop, mentor,

and lead people• Are respected for their technical

knowledge• Realize that problems are

opportunities for employee development

• Seldom give orders • Ask questions and get employee input



– A company developing its own leaders and defining the role of leadership as building a learning organization lays the groundwork for genuine long-term success.

– Continually reinforce the company culture and train exceptional people and teams to work within the culture to achieve exceptional results.


14 Principles of Lean Putting First Hand Experience Above All Else (1 of 4)

Principle 12: Go and See for Yourself to Thoroughly Understand the Situation—Genchi Genbutsu.

• Go to the place where the work is being done. Solve problems and improve processes by personally observing instead of relying or theorizing based on what others tell you or what you see on the computer.


14 Principles of Lean Striving for Continuous Improvement (1 of 12)

Principle 14: Become a learning organization through relentless reflection (hansei) and continuous improvement (kaizen).

• Once you’ve established a working process, use continuous improvement tools to address inefficiencies and apply counter-measures.


14 Principles of Lean Striving for Continuous Improvement (8 of 12)



Download “Lean Manufacturing” PowerPoint presentation

at ReadySetPresent.com

Slides include: Explanations of lean manufacturing, models and processes, 13 slides on eliminating waste, 6 slides on the lean house

model, 5 slides on long-term philosophy, 10 slides on creating continuous process flow, 9 slides on using pull systems to avoid overproduction, 10

slides on leveling out the workload, 13 slides on developing quality standards to get things right the first time, 9 slides on the standardization of tasks, 16 slides on using a visual control system to detect problems, 6 slides on using tested and proven technology, 9 slides on growing leaders from within, 11 slides on developing employees, 5 slides on working with

suppliers, 4 slides on the value of first-hand experience, 9 slides on careful decision-making, 12 slides on continuous improvement, action plans and

much more.

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Date post:	19-Sep-2014
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Lean manufacturing

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