Post on 17-Jan-2017
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Lean methodology
• Definition: To achieve a manufacturing cycle time of 5 days or less for standard products over 90% of the time.
• Key metrics:– Average Manufacturing Cycle Time– % of Units with an MCT of 5 days or less
• Scope: – Manufacturing Cycle Time (MCT) = Order release to
operations through shipment from manufacturing dock– Sales orders for standard end products
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Lean methodology
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Lean methodology / 4 quadrant chart
Action Plan Resp. Date Root Cause Analysis
1) Implement single piece flow to improve the A. Halteman 1/31/08 1) Batch processing is causing the cycle time in operations to be speed and repeatabiltiy through the greater than 5 days. production line
2a) Update published lead times to 2 weeks A. Halteman 1/18/08 2) The published lead time of 3 weeks has caused the delivery to reflect current process capabilities & J. Dillon expectations from our customers to be > 5 days.
2b) Reevaluate published lead times for A. Halteman 3/14/08additional potential reductions & J. Dillon
Sho-Rate Manufacturing Cycle Time - Dec FY08Four Quadrant Chart Analysis
Reasons for MCT > 5 days
0 100 200 300 400 500 600
Resources
Machined Part Shortage
Non-stock Tube
Other
Purchase Part Shortage
Shipped in 5 days
Req Date > 5 days
Number of Meters
Sho-Rate MCT by Unit
02468
101214161820
Jan-
07
Feb-
07
Mar
-07
Apr
-07
May
-07
Jun-
07
Jul-0
7
Aug
-07
Sep
-07
Oct
-07
Nov
-07
Dec
-07
Bus
ines
s D
ays
ActualTarget
LT distribution- Line #1
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2007M1 2007M2 2007M3 2007M4 2007M5 2007M6 2007M7 2007M8 2007M9 2007M10 2007M11 2007M12
%
Mon
th
Over 2 weeks
2 weeks
1 week
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Lean methodology / Report out
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Lean methodology / CPI
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Lean methodology / Pictures
Lean trainings – everyday examples
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I. Visual Control - No what is going on without anyone telling you o Highway and street signs o Traffic signal - red, yellow , green o Airport signs and display boards o Soccer game score board
II. Five S - Work place organization
o Performing and sustaining Spring Cleaning o See paper on the floor - add to it o See paper on the floor - leave it o See paper on the floor - pick it up o Personal involvement and encouraging to establish and maintain great
housekeeping o Inspecting areas for good housekeeping
III. Standardized Work - Finding the best routine and repeating it
o Your travel to work - the same way each day o Your daily routine - rise up from bed, brush your teeth, shower, dress
yourself o Your weekly routine - work, chores on Saturday and Church on Sunday o McDonald Restaurant - French fries taste the same regardless of location
IV. Kanban - Sell one, buy one
o Grocery store cereal o Milk in your refrigerator o Gas in your car