introduction to lean manufacturing
TRANSCRIPT
Lean Geek
Introduction to Lean Manufacturing
Paul Hill
What is Lean• Lean is a philosophy, an improvement process,
a way of leading, a business strategy, a competitive advantage, a means to save manufacturing.
• What lean means to me is the belief that we can make the world a better place one small improvement at a time, by identifying and eliminating waste from all that we do.
Image of Lean
Just-In-Time Autonomation
• Continuous Flow
• Takt Time• Pull System• Small Lots
• Stop and notify of abnormalities
• Separate man’s work and machine’s work
Stability and Standardized Work
Highest Quality, Lowest Cost, Shortest Lead Time
Visual ManagementLevel Production
P
DC
A
Lean Philosophy
Customer Focused Goals
Lean Philosophy1. Customer First2. People are the most valuable resource3. Continuous Improvement4. Shop floor focus
The Lean Goal–Highest Quality–Lowest Cost–Shortest Lead-time
What Gets In the Way
UnevennessOver Burden
Waste
What is Unevenness?• Fluctuation in demand running unchecked
through your organization.– This causes the need for excess capacity in
equipment and people to deal with the peaks, and a lot of idle time dealing with the troughs.
– Inventory is used to try and smooth out the peaks and valleys, but that causes other problems.
– Leveling the demand is one of the most important tasks in the implementation of Lean.
What is Overburden?• Working harder then needed, or pushing
equipment past the standard limits or duty cycle.– This causes breakdowns, and injuries.
• Leveling the work load as well as variety is the best way to avoid overburdening the people and the equipment.
WasteWaste is divided into 8 Categories
D – DefectsO – Over ProductionW – WaitingN – Non utilization of human potential
T – TransportationI – InventoryM – MotionE – Excess Processing
How much waste is in our life?
Opposite of waste is Value Add.Value add requires 3 things1. Change in the form fit our function2. Done right the first time3. Customer is willing to pay
If we look for the value add in life we realize almost all of the things we do are waste.
The War on WasteWith all of this waste in the way, we must declare war on waste. Unrelenting war.
The more waste we eliminate the more time we have for value add work.
What waste to eliminate first• Define the long term Vision– The Big Harry Audacious Goal (BHAG)
• Define the First Short Term Target– A next logical step towards your BHAG
• Identify the Waste in the way of reaching the target condition.
• Now rally the troops, and go to war on the waste standing between you and your target.
What does that look like
Current Condition
BHAG
Waste
WasteWaste
WasteWaste
Waste
Next Target Condition
Waste
Waste
WasteNext Target Condition
WasteWaste
Waste
WasteWaste
WasteWaste
Waste
Waste
Waste
Waste
The First Problem• Usually the first problem is not knowing
where you are.• This is typically caused by not having a
standard.• Two lean tools are usually used to solve this– 5S– Standardized work
What is 5S
Sort – remove unneeded items from the areaSet–in-Order – Provided a home for everythingShine – Clean and look for ways to keep cleanStandardize – The rules for the first 3Sustain – Maintaining the rules
What is Standardized Work• Standard work is our playbook – the safest, easiest,
and most effective way of doing the job that we currently know
• The purpose of standard work is to provide a basis for improvement.
• Standard work should Show :1. Work Content2. Sequence3. Timing4. Location5. Output
How to document STD WRK• Combination Table• Standard Work Chart• Work Balance Chart• Capacity Chart• Job Element Sheet
JIT Pillar
• Just In Time means delivering exactly what the customer wants, exactly when the customer wants it, in the Quantity and variety the customer wants.
• When looking at a Value stream and analysing the lead time much of the time is spent waiting.
• Just In Time tools are used to reduce the lead lime.
AutonomationAutomation with a human touch-Smart machines that stop before
making a defective part-Smart assembly line that stops
before making a bad part-The requirement of line
operators to stop the line when anything happens outside of the expected standard
Ji do ka
Ji do ka
Human
Small Simple Improvements• Taking small step, lots of singles will get closer
to the next target condition.• Each improvement is an exercise in Plan Do
Check Act.
PDCA
Plan – Define an action you wish to take and predict the result of the actionsDo – perform the action Check – Did you get the result you predictedAct – Make the action standard if you got the results you wanted, or Make a new plan.
Summary
• Know where you are– Standardized and make problems obvious
• Know where you want to go– BHAG
• Identify the your short term goal– Next Target Condition
• PDCA improve your way to the next goal• Many Lean tools exist to help you reach the next step• Small Steps are better than giant leaps
