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Lean:
Process based on the
fundamental goal of
eliminating waste and
maximizing flow.
Lean Objectives and goals
Define value from
customer perspectives
Reduce waste/improvequality
Utilize employee
potential
Standardize work
Balance workflow and
processes
Continuous improvement
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8 sequential steps used to implement Lean
concepts
Commit to LeanChoose the Value Stream
Value Stream= is the collection of steps that is needed to produce what thecustomer want
Learn about Lean
Map the current stateMap out everything that you are doing now.
Identify Lean Metrics
Identify the time it takes to complete all processes
Map the future state
Map the minimal collection of steps that is needed to produce what the customerwant
Create Kaizen plans(kai means take part and zen means make good
Small daily improvements made improved by everyone
Implement kaizen plans
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What is Lean Manufacturing?
A systematic approach to the identificationand elimination..of?
all forms of wastefrom the value stream.
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TPS Definitions of Waste
1. Overproduction
2. Waiting, including time in queue
3. Transportation (between workstations, or between
supplier and customer)
4. Non-value-adding activities / Over Processing
5. Inventory
6. Waste motion7. Cost of poor quality: scrap, rework, and inspection
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Benefits of Lean Manufacturing
(1) Lower production cost higher profits andwages
Cost avoidance flows directly to the bottom line.
(2) Supports ISO 14001 and "green"manufacturing
Reduction of material waste and associateddisposal costs higher profits
(3) Shorter cycle times: make-to-order vs. make-to-stock
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Control Surface Approach
Process
Control Surface
Material Inputs Material Outputs
Energy Inputs Energy Outputs
The material and energy balance is
standard practice for chemical process
design. Outputs must equal inputs.
Material outputs, for example, include everything that
is thrown away, as well as the product.
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So..
Most of lean manufacturing is
common sense!
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We can conclude that,
Business activities can contain enormousquantities of built-in waste (muda, friction).
The greatest obstacle to the waste's removal isusually failure to recognize it.
Lean manufacturing includes techniques forrecognition and removal of the waste.
This delivers an overwhelming competitiveadvantage.
This we will read as
GREEN OPERATIONS.
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5S-CANDO
5S-CANDO, a systematic approach to cleaning andorganizing the workplace, suppresses friction.
Seiri = Clearing up "When in doubt, throw it out."
Seitori = Organizing (Arranging) "A place for everything and everything in its place."
Seiso = Cleaning (Neatness)
Shitsuke = Discipline
Seiketsu = Standardization (Ongoing improvement,holding the gains)
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5S Performance Excellence Model
Systematic-Systematic
Organization
Scrubbing clean
Self-Discipline-
Control
For which this one?
Customer Expectations
Sorting Visual
Placement
Standardizing
Control
Improved Quality
Improved Safety
Reduced costs
Consistent Deliveries
Improved Product/ Service
Options
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Major CPITools (6s) Kaizen Lean Description
Cp/Cpk 4 Process capability assessmentDOE 4 Design of experimentsSPC 4 Process control based on statistics and data analysisFMEA 4 Risk assessment toolRegression 4 Correlate effect one variable has on anotherProcess Map 4 4 4 Map process steps to communicate and identify opportunities5 whys /2 hows 4 4 4 Determinationmethods for root cause discovery
Pareto 4 4 4 Column chart ranking items highest to lowestFishbone 4 4 4 Cause / Effect Diagram5S 4 4 Elimination wasteVisual Mgmt 4 4 4 Emphasis on visual techniques to manage processPoka-Yoke 4 4 Error proofing techniquesSpagetti Chart 4 4Kanban 4 4 Material storage technique used to control processTakt Time 4 4 Determine pace or beat of a processStd Work 4 4 Evaluate tasks done during a process
SMED 4 4 Single minute exchange of dies - Quick machine set upTPM 4 Integrate maintenance strategy with processCellular Flow 4 Reduce inventory & cycle time thru process layout and pull
production techniques
Expand Process Improvement Program to Utilize Kaizen Tool Kit
Tool Kit Comparison
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WASHINGTON
Gen. Stanley A.McChrystal, the leader of American and
NATO forces in Afghanistan, was shown a
PowerPoint slide in Kabul last summer thatwas meant to portray the complexity of
American military strategy, but looked more
like a bowl of spaghetti.
Spaghetti
SPAGHETTI
http://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://spaghetty....docx/http://spaghetty....docx/http://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-per8/2/2019 Lean Concepts
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Spaghetti Chartis used to detail the actual physical flowand distances involved in a work process. Processesthat have not been streamlined frequently are poorly laidout with work/product taking a path through the workarea that looks like a mass of cooked spaghetti.
To create a spaghetti chart you:
1. Create a scale map of a work station or work process2. Draw a line from the initial point of work to the next step
3. Continue until the work/product exits the work area
Examination of this resulting chart will show where
improvements are to be made
Spaghetti Chart
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Spaghetti Chart
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Waste Management
Waste Volume contents
Activity data collection (solid waste)
Waste categories
Overview of methodological issues and challengesin reporting
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Waste Volume1 Waste generation, composition and
management data
2 Solid waste disposal
3 Biological treatment of solid waste
4 Incineration and Open Burning of Waste
5 Wastewater treatment and discharge
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1. Activity data for solid waste
Waste generation, composition andmanagement data
encourage collection and use of country-specific
data (local conditions vary much; uncertainties for
default data large)
regional/country-specific default data on amounts,
management and waste composition
management data: solid waste disposal,incineration, composting and other (recycling)
consistent treatment across categories
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1. Activity data for solid waste1
Default waste categories: MSW, Sludge,
Industrial waste and Other
regional defaults for MSW components (paper,
food, wood, plastics, etc.)
defaults for carbon contents in the different waste
types
degradable organic carbon (SWDS) fossil carbon (incineration, open burning)
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2. Solid waste disposal
Significant source of methane Considerable time lag in emissions after disposal
- taken into account in the First order decay
model (revised from GPG2000; spreadsheet; can
be used for all Tiers) default parameters provided (updated values
- decay rates by climate zone)
default regional acitivity data (guidance howto estimate historical disposal)
methane recovery - guidance improved
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2. Solid waste disposal
Provide data for HWP estimates
FOD model produces estimates on carbon storage
in SWDS
only long-term carbon storage estimated
also corresponding methane estimates
carbon storage taken into account in the
AFOLU/HWP section => long-term carbon storagereported as an information item in the Waste
sector
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2. Solid waste disposal
Box 3: Tier 3
Estimate Emissions using
the IPCC FOD method
with default data to fill in
missing country-specific
data
Collect current wastedisposal data and
estimate historical
data using guidance
in Section 3.2.2.
Yes
No
No
No
Box 1: Tier 1
Estimate emissions
using country-specific
methods or IPCC FOD
method with country-
specific key parameters
and good quality
country-specific activity
data
Box 2: Tier 2
Estimate emissions using
the IPCC FOD methodwith default parameters
and good quality country-
specific activity data
Yes
Yes
Start
1Good quality country-specific activity data mean country-specific data on waste disposed in SDWS for 10 years or more.
2Key parameters mean DOC/Lo, DOCfand half-life time
3
See Volume 1 Chapter 4, "Methodological Choice and Identification of Key Categories" (noting Section 4.1.2 on limitedresources), for discussion ofkey categories and use of decision trees.
Are
good quality
country-specific activity
data on historical and currentwaste disposal1
available?
Arecountry-specific
models or key
parameters2
available?
Is
solid waste
disposal on land a key
category3?
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3. Biological treatment of solid waste
GHG (CH
4, N
2O) emissions from biological
treatment small (CO2 not taken into account
as of biogenic origin)
simple methdology - activity data times
emission factor (defaults provided for
composting and anaerobic digestion)
energy use of methane from anaerobic
digestion => emissions from combustion to be
reported in the Energy sector
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4. Incineration and open burning of waste
Waste-to-energy reported in the energy sector
CO2 from fossil waste fractions (plastics, waste oils,etc.), N2O and CH4
open burning - new category; important indeveloping countries
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5. Wastewater treatment and discharge
Improved guidance (incl. tier-structure)
wastewater and sludge - emissions duringtreatment estimated together (organic matter in
sludge disposed at SWDS, spread in agricultural
soils or incinerated subtracted) uncollected wastewater methodology
N2O - methodology also for industrial waste water
treatment