ten steps to lean production

Ten Steps to Lean Production

Steps to CIM

1. Re-engineer (revisit, replan)

the manufacturing system• Form U-cells to produce

families of parts (clusters)

• Integrate production, inventories, Quality Control and machine tools

Steps to CIM

2. Setup reduction or elimination

• Identify elements that are “internal” and those that are “external”

• Improve methods (use a pit crew)

• Re-engineer to eliminate adjustments, mechanize, automate

Steps to CIM

3. Integrate quality control into the system

• Develop a systems approach

• Incorporate visual signals• Work toward a “1 piece

flow” Make 1, check 1, move 1 on

Steps to CIM4. Integrate preventative maintenance

into the system• Reduce pressure on workers and the

process (back off from 100%)• Housekeeping – place for everything

and everything in place• Decrease system variability

Learning Loops in CIM

Steps to CIM

5. Level, balance, sequence and synchronize

• “Smooth” manufacturing• Keep production “level”• Make production “predictable”• Incorporate “kanban” labelling

Label

Steps to CIM6. Production Control

• Integrate scheduling and control functions into the system

• Use MRP/ERP software • Use the PC system to link cells together

• MRP = Manufacturing• ERP = Enterprise• DRP = Distribution• CRP = Capacity• BRP = Business

Schematic factory layout

Steps to CIM7. Reduce work-in-process

• Excess inventories hide problems• Reduce the inventory to expose problems• Take immediate action to eliminate the

problems                                                                                                                                                                

Steps to CIM8. Integrate suppliers

• Work to reduce suppliers to a single source

• Develop trust & open communications• Implement flexible procurement (supply

purchasing) contracts• Develop long-range forecasts

Steps to CIM9. Automation

• Allow workers to control the process (trust in work force)

• Provide clear directions• In-process controls and inspections• Feedback loops

Steps to CIM10. Computer-Integrated

Manufacturing• Enterprise-wide systems• Remove functionality

(independence) of departments• Focus teams on product lines and

customers

The REAL Goal is to become LEAN

• Waste eliminated• Employees involved• Customers satisfied• Profits increased• Company survival assured

By printing and binding in the same factory, Butler and Tanner reduces the amount of transport required during the production process

Achieving CIM• Toyota has been on a

“journey” toward a waste free and coordinated operation for 45 years… and they know they are not there yet.

• The “steps” and “tools” help people understand the process of change, but there is much more that is required