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LEAN BASICS, LEAN MODEL,
TFM, TPM, TQM, TSM, THM, JIT,
LEAN Six Sigma – SIMPLIFIED !!
Lean Coach : Nilesh Arora
Lean Basics
www.avci-lean.com Email : [email protected]
Operations Excellence Team Excellence
Business Excellence
Asia Africa Australia
Creating World Class Organizations …
In 9 Simple Steps
By
ADDVALUE Consulting Inc.
What is Muda ??
Muda = WASTE in any activity Removal of Waste = Low Through Put Time (TPT)
Increase in Value Addition Ratio
By Identification, Reduction, Elimination of Waste
on a Continual basis helps Organizations become
WORLD CLASS, LEAN, FIT, COMPETITIVE &
SUSTAINABLE
What is Lean ?
“To achieve EXCELLENCE or even PERFECTION
by continual
IDENTIFICATION, REDUCTION & if possible ELIMINATION
of Muda (Waste - NVA)
across the value chain”
TOTAL LEAN MANAGEMENT ATTACK MUDAs
Identify Reduce Eliminate
MUDAs
thru
VALUE ADDING
WORKSHOPs
VAWs
World Class, Lean, Fit, Competitive &
Sustainable Organizations
Unawareness of Lean Management Tools
Muda of Transportation Muda of Motion
Muda of Waiting Muda of Rejection Muda of Over Processing Muda of Inventory
Muda of Over Production Muda of Unused Human Potential
Creating World Class Organizations
Creating Lean Foundations through TOP Management Commitment & 5S
Creating World Class Organizations = “TOTAL LEAN MANAGEMENT”
TFM TPM TQM TSM THM
SUPPL I ERS
CUSTOMERS
TOTAL
FLOW MANAGEMENT
TOTAL
PRODUCTIVE MAINTENANCE
TOTAL
QUALITY MANAGEMENT
TOTAL
SERVICE MANAGEMENT
TOTAL
HUMAN MANAGEMENT
Identify, Reduce & Eliminate Muda (Waste) Continually - across the Value Chain
Focus
on
Quality, Cost
& Delivery
Focus
on
Quality, Cost
& Delivery
ADDVALUE Through
TOTAL Employee Involvement
(TEI)
Continual Process Improvements Zero Defects
Application of Lean Tools
( AVCI- 9 steps)
Lean Pillars and Tools
Lean Pillars Lean Tools
TFM 5S, Spaghetti Diagram, Value Stream Mapping (VSM), Cellular Manufacturing, Lean Business Process, Lean Office
TPM Autonomous Maintenance, Planned Maintenance, Quick Changeover (SMED)
TQM 7 QC Tools, Problem Solving, Poka Yoke, Lean Six Sigma
TSM Kanban, JIT, Spares Management, Lean Distribution, Lean Logistics, Lean Supply Chain
THM Lean Org Structure, Lean Metrics, Lean KPIs, Lean Appraisals, Lean Counseling
TFM (Total Flow Management)
Production Flow Internal Logistics Flow External Logistics
5.Low Cost Automation 4. SMED 3. Standard Work 2. Cellular Layout 1. Line and Layout Design
5. Production Pull Planning 4. Leveling 3. Synchronization 2. Mizusumashi 1. Supermarkets
5. Pull Planning 4. Deliver Flows 3. Source Flows 2. Milk Run 1. Storage & W/house Design
TPM (Total Productive Maintenance)
TOTAL PRODUCTIVE MAINTENANCE
LEA
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& T
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ING
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AIN
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LEA
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E
SAFE
TY &
EN
V.
5S – (Seiri, Seiton, Seiso, Seiketsu, Shitsuke)
TPM Basics
TQM (Total Quality Management)
LEVEL 0 LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4
GOAL Not Defined “servicing”
Reduction of Customer Complains
Reduction of Internal Complains
Reduction of Interfaces Complains
Zero Defects Value Stream Chain
SITUATION Defect products leave the company
Defect Reduction through Inspection
Defect reduction by defect prioritization
Defect reduction by interface optimization
Defect prevention with optimized process
KEYS Defect rate >15% high non conf. cost
Defect rate < 15% red. External defects
Defect <5% (50,000 ppm) red. External defect cost
Defect rate <10.000 ppm invest in appraisal
Defect rate <100 ppm Invest in Protection
FOCUS Manual Workplace Operations Int. Sub-processes Internal process Whole entity
TOOLS QC tools little known, Non systematic use of QC tools
Statistical process Control, Poka yoke
Structure problem solving with Kaizen
Structured Problem Solving with Six Sigma
Benchmarking, Design for Lean Six Sigma
PEOPLE No or less people Involvement
Centrally organized Quality administration
Beginning involvement employees participate and are responsible
50% involvement HR-Instruments Ind. Development
100% people involvement, 100% responsibility, 100% development
TSM (Total Service Management)
BEST IN CLASS Create Waste free procedures , Become a Show Case
Achievement of QCDMS
targets
L6
Control Process to become
FLEXIBLE WORKING
IN TEAMS
Analyze Task, Apply Mobility concept, Create flexible workstations & Layouts
Greater flexibility less
space
L5
Empower People For
Optimization as a Team
Implement Visual Management, Create Team boards
VM, Policy Deployment
L4
Lock in Gains By
Process Improvement
Map document and Information Flow, Do PDCA, Leverage IT
Reduced Lead Time, Paper less Office
L3
Save Through
Co-Operation Standardize – Procedures & forms, Officer materials, Communication
No errors or omissions
L2
Improve Through
Self Organization
Eliminate Muda, Do 5S, Set Goals, Develop Roadmap
Awareness of Waste
L1
Create a good foundation Through
THM (Total Human Management)
Lean KPI
Self Assessment System
Safety & Morale
Lean Counseling
Merit Rating System
Human Resource Development System
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Creating World Class Organizations in 9 Simple Steps…
Lack of awareness of Lean Management tools
Muda of Transportation
Muda of Motion
Muda of Waiting
Hands-on Training
TFM
5S + Muda, Mura, Muri Elimination
Muda Of Unused Human Talent
Muda of Over Production
Muda of Inventory
Muda of Defects / Rework
Muda of Over Processing
Kanban, TSM
One piece / Small Batch Flow, JIT, Pull Manufacturing
Total Human Management (THM)
Lean Six Sigma, Process Standardization
TFM,TPM,TQM, Lean Office
TPM, TQM, Lean Office
Identify Reduce
Eliminate MUDAs’
ADDVALUE at each step
Using LEAN TOOLS
Step 1
WORLD CLASS Organization
Lean Summarized
Lean Benefits
• Aligned vision
• 30-40% release of space
• Through Put Time reduction
• Inventory reduction by 40 %
• 50% reduction in errors, eventually Zero Defect Manufacturing
thru Six Sigma
• Improved cash flow
• 15-20% increase in profitability
• Improved team work
Test Your Lean IQ - ADDVALUE Lean Quiz
