Lean Basic for Training
description
Transcript of Lean Basic for Training
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1885
1913
, , , .)
1955-1990
1993-
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!!
...More details to come
Define Value
Value Stream Map /
Pull Production
Continuous Flow
Strive for Perfection)
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Overproduction
Transportation
Inventory
Waiting
Processing
Rework
Motion
Intellect
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Cola
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First Time
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ValuePrice
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3 forms a minute
1 batch per minute
6 0 s ec Tak t
1 Batch 1 Batch 1 Batch 1 Batch 1 Batch 15 Batches 1 Batch 1 Batch 1 Batch 1 Batch 1 Batch 1 Batch
40 Forms 60 Sec 30 Sec 30 sec 100 Sec 20 Sec 20 Sec
Walk Walk Walk Walk walk walk
VA 60 30 30 100 20 20 20 280 VA
NVA 800 60 15 60 30 15 30 30 15 900 100 15 20 20 30 15 20 20 2195 NVA
40/3
Time is approximate. VAR 0.113131
11%
AS IS VSM speedy Corporation By Jerry Coover Date 12-14-04
Customer
Supplier
if used
WS 1
numbers
1 to 10individual
blank
forms
Batch
Work station 2
A to F
Batch
Work station 2
A to F
Batch
Work station 2A
G to Z
Batch
Work station
3
Red / Blue
slash
Batch
Work station
4
QA.WalkWalkWalkWalkWalk
Verbal
Make as many
as possible
Batch
Finished
Goods
FinishedGoods
Walk
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I50 pcs.
3
C/T= Oper. 12 secsMach. 30 secs
C/O = 15 mins.
Uptime= 75 %
3Reject rate= 13%
2-X/wk.
Push Arrow
F I F O
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Daily Schedule
Withdrawal Kanban Production KanbanSignal Kanban
OXOXLevel Loading
Heijunka BoxKanban Mailbox
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(CT)
CT
(VCT)
VCT
(LT) Lead Time.
LT
: VCT < CT < LT
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2X/day
CustomerSuppliers
Cook Dogs Put in Bun Wrap/Freeze
C/O = 5 mins.
Uptime = 85 %
Scrap Rate = 13%
1 Operators
C/O = 0 mins.
Uptime = 100%
Scrap Rate = 9%
1 Operators
C/O = 3 mins.
Uptime = 90 %
Scrap Rate = 5%
1 Operators
I
130 dogs
I
60 dogs
I
150 dogs
I
515 dogs
Material Control
Make
Hot Dogs
I300 buns
Cut Buns
C/T=Oper. 11 secs
C/O = 0 mins.
Uptime = 100 %
Scrap Rate = 9%
1 Operators
I
345 buns
Order
Forecast
Order
Materials
Daily
Order
960 Hotdogs/day
2 shifts
Shipping
Staging
600 buns and dogs
per load
TAKT Time = 60 Seconds
Leadtimes
(TT x #pcs)
300 mins.345 mins.
Value-added
times
Value Added Time128 sec
150 mins.130 mins. 60 mins.515 mins.
515 mins 130 mins 60 mins 150 mins
Prod Lead Time
855 min = 51300 sec
C/T=Oper. 12 secs
Mach. 42 secs.
54 secs
54 sec
C/T=Oper. 17 secs
17 secs
17 sec
C/T=Oper. 22 secs
Mach.:35 secs
57 secs
57 sec
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5S
5S
5S
5S
5S.
5S
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5S
5Ss:
Step 5:
Step 4:
Step 3:
Step 2:
Step 1:
SustainingShitsuke
StandardizeSeketsu
ShiningSeiso
StorageSeiton
Sorting
Seiri
5 S is not a Japanese I dea. I t is good common sense!
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(Sorting)
Sorting
Red Tag
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Storage
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Shining
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Standardizing
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5S
30!
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Sustaining
Checklist
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5S
5S
5S
5S
5S:
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(cont.)
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VisualAudio
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(Poka-yoke)?
Poka-Yoke(poka)(yokeru).
Poka-YokeShigeo Shingo.
Poka-YokeShigeo Shingo
.
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100%
100%100%
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Park
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New Worker
Forgetfulness
Willful Errors
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Lack of Standard
Surprise Errors--Equipment
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Defects
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Takt Time.
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Takt.
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Volume ()Time ()
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Cycle Time:
Takt Time:
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Takt time
Op1 Op3 Op4 Op5 Op6
Op2
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Standard Operations
ACME
Standard Operations
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Standard Operations
1..2..3.
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Kanban Square
Signal Kanban
Material Kanban
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X X X
XX
X
Signal Kanban
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Signal Kanban
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( .)
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(.)
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407 408 409
( .)
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407
408
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407
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(.)
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!409!
407
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Production Kanbans
Withdrawal Kanbans
Supplier Kanbans
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B
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FIXED ORDER CYCLEKANBAN ORDER SUPPLIER TIME RETURN TOCOLLECTION LOTSIZING FAX TO DOCK POINT OF USE
(If Required)
NOTE: UNIQUE PURCHASED PART (SP)
CONSTANT ORDER CYCLE
(COMMON CARRIER)STAGING POINT:
DEPT 13
ORDER CYCLE
WEEKLY
SUPPLY POINT: MATL.
PLANNERS
BOX/RECEIVING
PRESSED METALS
REF.DRAWNINGNO.
CONTAINER TYPE:
BOX
KANBAN QUANTITY
1500
PART NAME
BUSHING
SUPPLIER KANBAN
PART #
KANBAN #
____ OF ___
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TPMTotal Productive Maintenance
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Total Productive Maintenance
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TPM .
TPM
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Equipment Operator
Maintenance Personnel
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Reactive
.
Preventative
.
Predictive
.Product
or
Process
Fa il u re Mode Fa il u re E ffec ts
S
E
V
Causes
O
C
C
Controls
D
E
T
R
P
N
Actions Plans PS
PO
PD
p
rp
n
Reactive
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Preventative Maintenance
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100
Preventative Maintenance
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Product or
Process
Failure Mode
Failure
Effects
SEV
Causes
OCC
Controls
DET RPN
Actions Plans
PS PO PD Prpn
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Preventative Maintenance Diagnostics
Thermistor
Thermometer
,,
Infrared
Accelerometer Stethoscope
Stroboscope
Laser alignment
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X-
/
Ph
Preventative Maintenance Diagnostics
Predictive Maintenance
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Six Big Losses
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1. Breakdown losses
2.Set-up and Adjustment losses
3.Minor stoppage losses
10
4.Speed losses
5.Quality defects and rework losses
6.Yield losses /)
TPM
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TPM:
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TPM23.
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Total setup time
internal external
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%
?
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o
o
o Fixed Stops
oo
4
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No Dial
Indicators
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Fastening
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10
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S.P.C.
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Die or Fixture MovementTightening or LooseningAutomatic AdjustmentsPallet SystemsTool Changers