1-lecture1 lean intro
DESCRIPTION
mTRANSCRIPT
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Dr. Rupy Sawhney
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Module Week
Fundamentals of Lean Enterprise Systems
1
Designing & Modeling of Lean Systems
2 & 3
Reliability of Lean Systems 3
Analysis of Lean Systems 4
Project-oriented week presentations 5
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June 30 July 1 2 3 4 5 6
7
from TYS Airport from TYS Airport
Sunday
Early Check-In Check-in Late Check-in
Monday Tuesday Wednesday Thursday Friday Saturday
Fundamentals of Lean Enterprise Systems (Intro to phylosophy and tools)
(10-11:30)
Foundry 8-12
I-house 1:30 - 3:30
Opening Ceremony
Orientation
(10-11:30)(10-11:30)
(extra cost)
(10-11:30)
UT Transportation
provided
UT Transportation
provided
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Dr. Rupy
Sawhney
MS.
Bharadwaj
Venkatesan
Experienced consultants from CIS
Misty DePriest
MS. Enrique
Macias de
Anda
MS. Isaac
Mitchell
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You must've heard an old sea story about a ship's Captain who inspected his sailors, and afterward told the first mate that his men smelled bad.
The Captain suggested perhaps it would help if the sailors would change
underwear occasionally. The first mate responded, "Aye, aye sir, I'll see to it immediately!"
The first mate went straight to the sailors berth deck and announced, "The
Captain thinks you guys smell bad and wants you to change your underwear."
He continued, "Pittman, you change with Jones, McCarthy, you change with Witkowski,
and Brown, you change with Schultz."
THE MORAL OF THE STORY: Someone may come along and promise
"Change", but don't count on things smelling any better.
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What Does History Teach Us ?
Panhard
&
Levassor
Henry Ford
& GMs Alfred Sloan
Niche
Markets (Aston)
Past Craft Production WWI Mass Production 1960 Lean Production Now
Toyotas Eiji Toyoda
&Taiichi Ohno
Out of business Out of business
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Cost increase What do we do?
MARKET COMPETITION
TODAY PRICE OF MP3 Players
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COST OF OUR PRODUCT
Fre
iva
lds, A
nd
ris (
20
09
),
Nie
be
ls M
eth
od
s, S
tan
da
rds, a
nd
Wo
rk D
esig
n
12
th E
d. M
cG
raw
Hill
, N
ew
Yo
rk,
U.S
.A.
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What if
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Cost increase What do we do?
1. INCREASE PRICE AFTER
CRISIS PRICE OF MP3 Players
After increase in price, the possible effects are:
1. Market share loss
2. Sales reduction
3. Profit reduction
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2. REDUCE PROFIT
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3. REDUCE WASTE
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Ben-Hur (1959), http://theworldofjot29.blogspot.com/2012/09/ovp-ben-hur-1959.html
http://www.allempires.com/Forum/forum_posts.asp?TID=30714
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Values
Culture
Principles
Your Leadership
Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization
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Values
Culture
Principles
Your Leadership
Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization
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Is This Value?
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Current Competitive Dimensions:
Value = Quality + Price + Delivery
Value Manufacturing Competitive Dimensions :
Value = Quality + Price + Service + Innovation
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What Are The Dimensions On Which Lean
Allows You To Compete?
Cost
Quality
Delivery
Others?
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Values
Culture
Principles
Your Leadership
Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization
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Your Desired Culture is Defined
By What?
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Values
Culture
Principles
Your Leadership
Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization
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Lean Lean focuses on eliminating non-
value added steps and activities in
a process.
Lean makes sure we are working on the right activities.
Lean establishes the value flow as pulled by the customer.
Six Sigma Six Sigma focuses on reducing
variation from the remaining value-
added steps.
Six Sigma makes sure we are doing
the right things right the very first time.
Six Sigma makes the value flow
smoothly without interruption.
Source: Air Academy Associates
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A business system that connects and empowers employees to
improve the value of our products
and services to customers by
reducing waste and producing what
is required.
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Specify value in the eyes of the
Identify the value stream and
Make at the pull of the customer.
Involve, align and empower .
knowledge in pursuit of
perfection
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Waiting
Conveyance
Inventory
Motion
Processing
Employee creativity
Poor quality
Scrap
Rework
Correction
Overproduction
100% inspection
Overtime
Added operations
Increase of variance
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Four Pillars
Appropriate Systems
Employees
Capability
Continuous Improvements
Shop Floor Guidelines
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IN COMMON SENSE TERMS
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LEAN TRAINING
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QUESTIONS