SKBSKB
Lean Production SystemLean Production System
2 - 2 2 - 2SKBSKB
Simulation 1 & 2Simulation 1 & 2
2 - 3 2 - 3SKBSKB
Kaizen Breakthrough Methodology
Focus on lead-time reduction to:Focus on lead-time reduction to:Increase customer loyalty and market shareIncrease customer loyalty and market share
Achieve growth in sales & earningsAchieve growth in sales & earningsSustain the competitive advantagesSustain the competitive advantages
Improve stakeholder valueImprove stakeholder value
Lean TransformationLean Transformation
Lean Production SystemLean Production System
Six Sigma Process Capability
2 - 4 2 - 4SKBSKB
Lean Lean Production SystemProduction System
JustJustinin
TimeTime
JustJustinin
TimeTimeJidokaJidokaJidokaJidoka
Efficient Use of: People Equipment Materials Space
Production SmoothingProduction Smoothing
Improve process capability
Minimize variation Manage abnormality
Drives cost reductionDrives cost reduction
Lean Production SystemLean Production System
2 - 5 2 - 5SKBSKB
Just-In-Time Is...Just-In-Time Is...
A manufacturing system which produces:
What the customer wants
In the quantity the customer wants
When the customer wants it
While using the minimum:
Raw materials
Equipment
Labor
Space
2 - 6 2 - 6SKBSKB
Lean Production SystemLean Production System
Key Concepts and Tools
Pace to Takt time
One-piece flow
Pull system
2 - 7 2 - 7SKBSKB
Importance of Takt TimeImportance of Takt Time
Customer requirements
Net operating time
Synchronizes operations to customer demand
Prevents overproduction
Tool for creating flow
Determines optimal staffing
Drives capacity analysis & equipment utilization
Must be updated periodically as demand changes
2 - 8 2 - 8SKBSKB
1-Piece Flow
Batch
Fake Flow
2 - 9 2 - 9SKBSKB
“A Sea of WIP”
“Now You See It!”
2 - 10 2 - 10SKBSKB
One-Piece FlowOne-Piece Flow
Supermarket Operation
AisleE D C B AI H G F
A B C D
E
F
GHI
2 - 11 2 - 11SKBSKB
Produce to Actual Customer Demand
Pull SystemPull System
2 - 12 2 - 12SKBSKB
Implement Pull SystemImplement Pull System
LSS
LSS
Pick-up kanban
Supplier
Supermarket
Dropproductionkanban
RMFG
Scheduleboard
Productionkanban
Wat
er S
pide
r
2 - 13 2 - 13SKBSKB
JIT ElementsJIT Elements
Small, inexpensive machines in process order
One-piece flow production, counterclockwise
Ergonomically-correct operations
Standing operations, moving while working
Pull system discipline
“Standard operations” defined and implemented
2 - 14 2 - 14SKBSKB
Simulation 3 & 4Simulation 3 & 4
2 - 15 2 - 15SKBSKB
JIT BenefitsJIT Benefits
Eliminates waste in production processes
Quality… Quality…
Cost… Cost…
Delivery!Delivery!
Creates a system which is intolerant of production abnormalities
Reduces lead times
2 - 16 2 - 16SKBSKB
Lean Lean Production SystemProduction System
JustJustinin
TimeTime
JustJustinin
TimeTimeJidokaJidokaJidokaJidoka
Efficient Use of: People Equipment Materials Space
Production SmoothingProduction Smoothing
Improve process capability
Minimize variation Manage abnormality
2 - 17 2 - 17SKBSKB
Jidoka is…Jidoka is…
A.A. A method for reducing defects
B.B.Equipment autonomation
to improve productivity
2 - 18 2 - 18SKBSKB
JidokaJidoka
A. Tools or Methods to Reduce Defects
Detect defects when they occur
Prevent defects from passing to next operation
Identify root causes of defects
Eliminate root causes
Reduce or eliminate defects
2 - 19 2 - 19SKBSKB
Jidoka ElementsJidoka Elements
Visual Control
5S
Andon
Abnormality Response/Reaction
Roles and responsibilities
Line stop guidelines
Sigma Kaizen (DMAIC)
Basic QC Tools
Advanced Statistical Tools
Countermeasures
Mistake-proofing (Poke-Yoke)
Manual Work
Automatic machine work
New Standard Operations and training
Skill matrix and performance
Autonomation
Separate person from machine
2 - 20 2 - 20SKBSKB
Jidoka ElementsJidoka Elements
Visual Control 5S
AndonParts
presentation
Tool presentation
Pack line
AndonStandard
work
2 - 21 2 - 21SKBSKB
Abnormality Response ProcessAbnormality Response Process
React to problem
Q C D S
Measure impact
Alert team
Train affected associates in new standard operations
MAN
EFFECT
MACHINE
MATERIALMETHOD
Find root cause
Develop and test improvement
Check 2B
Gauge 4
Update standard operations with tested improvement
2 - 22 2 - 22SKBSKB
JidokaJidoka
B. Equipment autonomation Separate operator work from machine work
Before: Operator watches machine run
After: Operator loads and moves Auto shut-off “Hanedashi” auto unload Operator moves to next operation
Question: Do you watch your dishwasher run?Question: Do you watch your dishwasher run?
2 - 23 2 - 23SKBSKB
Jidoka BenefitsJidoka Benefits
Increases production quality
Increases productivity
Ensures on-time delivery
Quality ... Cost ... Delivery!Quality ... Cost ... Delivery!
2 - 24 2 - 24SKBSKB
Lean Lean Production SystemProduction System
JustJustinin
TimeTime
JustJustinin
TimeTimeJidokaJidokaJidokaJidoka
Efficient Use of People Equipment Materials Space
Production SmoothingProduction SmoothingProduction SmoothingProduction Smoothing
Improve process capability
Minimize variation Manage abnormality
2 - 25 2 - 25SKBSKB
Production Smoothing Is...Production Smoothing Is...
Adapting production rates to variations
in customer demand
Variation in volume
Variation in product mix
2 - 26 2 - 26SKBSKB
Average Daily Demand = Target
Production
Quantity
Time
Customer Demand
Production SmoothingProduction Smoothing
Variation in Volume
2 - 27 2 - 27SKBSKB
Production SmoothingProduction Smoothing
Day
Monthly Schedule
(3200 units)
5 15 2010
Model A
1600 units
Model C
800 units
Model B
800 units
Day
Daily Schedule (160 units)
Production
pattern AABCAABC
80
1
40 40
80
2
40 40
80
3
40 40
80
20
40 40
Variation in Mix
2 - 28 2 - 28SKBSKB
Production Smoothing BenefitsProduction Smoothing Benefits
Maintains a consistent, high product quality
Reduces the requirements for capital investment
Reduces staffing costs
Ensures on-time delivery
Quality ... Cost ... Delivery!Quality ... Cost ... Delivery!
2 - 29 2 - 29SKBSKB
Drives cost reductionDrives cost reduction
Lean Lean Production SystemProduction System
Justin
Time
Justin
TimeJidokaJidoka
Efficient Use of: People Equipment Materials Space
Production SmoothingProduction Smoothing
Improve process capability
Minimize variation Manage abnormality