lean principles
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Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Lean Principles
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
• Lean is a systematic approach to process optimization based on the premise that anywhere work is done, some amount of waste (non-value add effort) is generated
• The goal is: Total elimination of waste (MUDA) through:
• Identifying the sources
• Planning for waste elimination
• Use of Lean, Process Management and Six Sigma
• Establishing “permanent” controls that prevent reoccurrence
• The first step toward waste elimination is identifying it
Lean Principles Definition
Move it!
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Examples of the 7 Areas of Waste
Seven Areas of WASTESeven Areas of WASTE
1. CorrectionCorrecting or repairing a defect in materials or parts adds unnecessary costs because of additional equipment and labor expenses. An example is the labor cost of scheduling employees to work overtime to rework defects.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
2. OverproductionProducing more parts than necessary.Producing parts at a rate faster than required.
Doing this requires more raw product inventory than necessary, over uses machines and people and requires more storage area.
Examples of the 7 Areas of Waste
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
3. Processing
Examples of the 7 Areas of Waste
Processing work that has no connection to advancing the line or improving the quality of the product.
Examples include typing memos that could be hand written or painting components or fixtures internal to the equipment.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Examples of the 7 Areas of Waste
4. ConveyanceConveyance is incidental, required action that does not directly contribute value to the product.
It’s vital to avoid conveyance unless it is supplying items when and where they are needed (i.e. just-in-time delivery).
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
5. InventoryInventory is a drain on an organization’s use of capital. The greater the inventory, the higher the carrying costs.
If quality issues arise and inventory perishes, defective material may be hidden in finished goods.
To remain flexible to customer requirements and to control product variation, we must minimize inventory.Excess inventory masks unacceptable change-over times, excessive downtime, operator inefficiency and a lack of organizational sense of urgency to produce product.
Examples of the 7 Areas of Waste
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Examples of the 7 Areas of Waste
6. MotionAny movement of people or machinery that does not contribute added value to the product; i.e., programming delay times and excessive walking distance between operations.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
7. Waiting Idle time between
operations or events, i.e. an employee waiting for machine cycle to finish or a machine waiting for the operator to load new
parts.
Examples of the 7 Areas of Waste
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Lean Value Stream Analysis
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Lean Value Stream Map
I
Coils5 days
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Person
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Person
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Person
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Person
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Stamping
1 Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
I I I I I
500 Ft Rolls
Tue. &Thurs
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.
A way of viewing the overall Value Stream, from supplier to the customer,
on one sheet of paper.
Enabling you to “see what is actually happening.”
Mon & Wed
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Why a Value Stream Analysis is Essential
1. It helps you visualize more than the just the single process level, i.e. order entry, invoicing, shipping, assembly, test, welding, etc. You can see the complete flow.
2. Value Stream Analysis is a qualitative process that allows you to understand in detail how your business should operate to achieve breakthrough performance levels.
3. It helps you see sources of inefficiency and problems in the complete generation and delivery of your service or product.
4. It forms the basis of an improvement vision and plan by helping understand how door-to-door flow should be performed to optimize costs, cycle times and quality.
5. It conceptualizes Six Sigma projects as well as other improvement efforts.
6. Value Stream Analysis is good for describing what you will do to change business-performance levels.
I
Coils5 days
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
Stamping
1 Person
C/T =Uptime =Run Hrs=Breaks=Hrs Avail=Sec. Avail=
I I I I I
500 Ft Rolls
Tues. &Thurs.
Pieces/Mo
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Shifts=
Delivery DPMO=
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BestMetal, Inc
Dellex
.Mon & Wed
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
• Value Stream Analysis puts the pertinent information about the total work effort of a product or service on one sheet of paper, the current-state map.• The human mind loses continuity and clarity when
information is fragmented across multiple places and sheets of paper.
• We can also map the information flow, i.e. customer and supplier ordering, production control, etc., to complete the picture.
• Overall performance and process-specific problem areas become visible for improvement actions.• This analysis can be done as a part of the overall
characterization of a process.
• The next step is to identify efficiency and effectiveness targets for the process.• The end result is a future-state map with a vision/plan
that is achieved through Six Sigma projects and other actions.
Value-Stream Analysis Summary
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
Applying the5S Principles
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
5S - Workplace Organization
• 5S means the workplace is clean, there is a place for everything and everything is in its place.
• 5S is the starting point for implementing improvements to a process.
• To ensure your gains are sustainable, you must start with a firm foundation.
• Its strength is contingent upon the employees and company being committed to maintaining it.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
5S Translation - Workplace Organization
Step Japanese Literal Translation English
Step 1: Seiri Clearing Up Sorting
Step 2: Seiton Organizing Straightening
Step 3: Seiso Cleaning Shining
Step 4: Seketsu Standardizing Standardizing
Step 5: Shitsuke Training & Discipline Sustaining
Focus on using the English words, much easier to remember.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
SORTING - Decide what is needed.
Definition:• To sort out necessary
and unnecessary items.• To store often used
items at the work area, infrequently used items away from the work area and dispose of items that are not needed.
Why:• Removes waste.• Safer work area.• Gains space.• Easier to visualize the
process.
Things to remember• Start in one area, then sort
through everything.• Discuss removal of items
with all persons involved.• Use appropriate
decontamination, environmental, and safety procedures.
• Items that cannot be removed immediately should be tagged for later removal.
• if necessary, use movers and riggers.
Things to remember• Start in one area, then sort
through everything.• Discuss removal of items
with all persons involved.• Use appropriate
decontamination, environmental, and safety procedures.
• Items that cannot be removed immediately should be tagged for later removal.
• if necessary, use movers and riggers.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
A Method for Sorting
Dispose
UselessSorting
Keep & Monitor
Unknown Useless
Item
Keep &
Store
Useful
Useful
ABC Storage
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
STRAIGHTENING – Arranging Necessary Items
Definition:• To arrange all necessary items.• To have a designated place
for everything.• A place for everything and
everything in its place.• Easily visible and accessible.
Why:• Visually shows what is required or
is out of place.• More efficient to find items and
documents (silhouettes/labels).• Saves time by not having to
search for items.• Shorter travel distances.
Things to remember• Things used together
should be kept together.• Use labels, tape, floor
markings, signs, and shadow outlines.
• Sharable items should be kept at a central location (eliminated excess).
Things to remember• Things used together
should be kept together.• Use labels, tape, floor
markings, signs, and shadow outlines.
• Sharable items should be kept at a central location (eliminated excess).
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
SHINING – Cleaning the Workplace
Definition:• Clean everything and
find ways to keep it clean.
• Make cleaning a part of your everyday work.
Why:• A clean workplace
indicates a quality product and process.
• Dust and dirt cause product contamination and potential health hazards.
• A clean workplace helps identify abnormal conditions.
Things to remember• “Everything in its place” frees
up time for cleaning.• Use an office or facility layout as
a visual aid to identify individual responsibilities for cleaning. This eliminates “no man’s land.”
• Cleaning the work area is like bathing. It relieves stress and strain, removes sweat and dirt, and prepares the body for the next day.
Things to remember• “Everything in its place” frees
up time for cleaning.• Use an office or facility layout as
a visual aid to identify individual responsibilities for cleaning. This eliminates “no man’s land.”
• Cleaning the work area is like bathing. It relieves stress and strain, removes sweat and dirt, and prepares the body for the next day.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
STANDARDIZING – Creating Consistency
Definition:• To maintain the
workplace at a level that uncovers problems and makes them obvious.
• To continuously improve your office or facility by continuous assessment and action.
Why:• To sustain sorting,
storage and shining activities every day.
Things to remember• We must keep the work place
neat enough for visual identifiers to be effective in uncovering hidden problems.
• Develop a system that enables everyone in the workplace to see problems when they occur.
Things to remember• We must keep the work place
neat enough for visual identifiers to be effective in uncovering hidden problems.
• Develop a system that enables everyone in the workplace to see problems when they occur.
Lean Six Sigma Awareness Copyright OpenSourceSixSigma.com
SUSTAINING – Maintaining the 5S
Definition:• To maintain our
discipline, we need to practice and repeat until it becomes a way of life.
Why:• To build 5S into our
everyday process.
Things to Remember• Develop schedules and
check lists.• Good habits are hard
to establish.• Commitment and
discipline toward housekeeping are essential first steps toward being world class.
Things to Remember• Develop schedules and
check lists.• Good habits are hard
to establish.• Commitment and
discipline toward housekeeping are essential first steps toward being world class.
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