© ABSL Power Solutions 2007© STM Quality Limited

STM Quality LimitedIntroduction to

Lean Manufacturing

TOTAL QUALITY MANAGEMENT

Lean Manufacturing

© STM Quality Limited

STM Quality Limited

Definition of Lean Manufacturing

“The production of goods using less of everything by reducing ‘waste’ and

increasing value added activity”

If it doesn’t add value, it adds cost!

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STM Quality Limited

Preparing for Lean Manufacturing

Five Lean Principles

Specify Value

Identify what the customer actually wants• Would you pay for something you didn’t want?• If it’s not adding value, it’s adding cost!

Identify theValue Stream

Identify the whole process (mapping) • What are the facts about our process capability?• What ‘waste’ is there in the process?

Make productflow

• Eliminate bottlenecks or manage them better • Reduce or avoid ‘batch & queue’• Get the maintenance right

Let the customer pull

Only make what the customer requires, when the customer wants it.

ContinuousImprovement

Increasing personal & company knowledge to pursue the complete elimination of waste.

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STM Quality Limited

Preparing for Lean Manufacturing

Reduction & elimination of ‘waste’ elements in the process Equipment reliability – Planned Preventative Maintenance (P.P.M.) Autonomous Maintenance & Condition Monitoring Continuous flow - one part at a time (JIT) & pull ‘Kanban’ systems Inventory (WIP) reduction throughout the process Defect reduction - right first time, error proofing & training Visual management – simple measures (KPI’s) & drumbeat Quick machine changeovers (SMED) Teamwork & communication Point of use storage but not ‘nests’ Bottleneck management

So what does ‘best’ look like?

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STM Quality Limited

Preparing for Lean Manufacturing

Disorganised Organised

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STM Quality Limited

Process Mapping

A process is…

A set of activities which convert inputs to outputs to meet agreed customer requirements.

“Draw a flow chart of what you do. Until you do, you do not fully understand what you are doing, you just have a job”

Dr W.E.Deming

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STM Quality Limited

Process Mapping

Characteristics of an ideal process…

– Each step adds value

– Each step is carried out only once

– Steps are carried out in the best sequence

– Uses the optimum level of resource

– Meets customer needs consistently

– Minimum space requirements

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STM Quality Limited

Why Process Map?

Biggest tool in lean – all others are deployed from mapping output

Big picture – detail comes later

Establishes real priorities by those who do the work – action plans with names & dates

Dramatic short & medium-term results

Idea generation & team involvement in decision making

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STM Quality Limited

Process Atlas

Customer needs CORE PROCESSES Satisfied Customer

KPI’s

MANAGEMENT PROCESSES

STRATEGY

DATA

SUPPORT PROCESSES

RESOURCES

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STM Quality Limited

Boundaries and Scope

Start to finish… order enquiry to receipt of payment or tighter definition we can influence?

All possible products or ‘runners’ only? Think flow & volume

What functions do we need involved beyond this room both internal & external?

Is there an obvious need for more information at this stage?

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STM Quality Limited

Lean Wastes

The ‘8 Lean Wastes’ (7 + 1)

Introduction to ‘TIM WOODS’

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STM Quality Limited

TIM WOODS

T – Transport

I – Inventory

M – Movement

W – Waiting

O – Over-processing

O – Over-production

D - Defects

S - Skill