LEAN LIFE" LEAN ORGANIZATION ISM NY /NJ FORUM 2011 Michael T. Walsh, CPIM, LSSBB The Quality...

“LEAN LIFE"

LEAN ORGANIZATION

ISM NY /NJ FORUM 2011

Michael T. Walsh, CPIM, LSSBBThe Quality Solutions Group

www.QSG.net

The Quality Solutions Group, LLC © All Rights Reserved 2

INTRODUCTION

WHOthe HELL are YOU and WHY are YOU HERE?

The Quality Solutions Group, LLC © All Rights Reserved

The Importance of Waste Elimination

Lean deals with the elimination or reduction of many types of non value added activities, often referred to as waste. ◦ The driving force for waste

elimination is improved value in the products and services customers buy.


Waste Elimination: The Seven Popular Wastes

1.Overproduction2.Waiting3.Excessive Transportation4.Inappropriate Processing5.Unnecessary Inventories6.Unnecessary Motion7.Defects

Taiichi Ohno, Toyota Production

System


We hear what we want to hear No Sweat, No Effort, No Strain Secret of the astronauts Eat what you want and still lose

weight New Technology – Clinical Studies Just 10 Minutes a Day Fast results quickly Just take a pill and get rid of the FAT Fat burns off while you sleep Have Pizza, Beer, Nachos – No

Problem


Common Disclaimers (for diets and diet plans)

Results may vary………. Results not typical… Unique experience… Don’t try this at home………. Professional Drivers - Closed

Track… Your particular body type,

metabolism, size, height, weight, etc.., may not provide blah, blah, blah……………

Consult a Physician………. Results projected with a combined healthy diet and an exercise

program……


How does one get lean (personally)?

Healthy DietExerciseWeight ControlReduction in Stress Lifestyle Management

Long term change in behavior


Lean Implementation Methodology?

1. Leadership

3. Just inTime Techniques

4. Controlling Processes

5. Standardizing Work

6. Continuous Improvement

2. Transparent Workplace


Leadership


Leadership Function

An important function of leadership is to bring about needed change by identifying a vision, aligning employees to that vision, and then motivating them to achieve that vision.


Visual Workplace


Visual Management

3 boxes maximum

1 box minimum


Just – In - Time


Quality Costs

Before After

failure

appraisal

prevention

failure

appraisal

prevention

QualityCosts

Before After

failure

appraisal

prevention

failure

appraisal

prevention

QualityCosts


Process Control


Parking height barsArmrests on seats

Poka Yoke Methods and Examples

Contact

Fixed Value

Motion Step

Control Warning

Staff mirrorsShop entrance bell

French fry scoopPredosed medication

Trays with indentations

Airline lavatory doorsSpellcheckersBeepers on ATMs

– Richard Chase and Douglas Stewart, Mistake Proofing Based on Shigeo Shingo


Standard Work


Standardized Process Chart

Doing the work Checking key Respondingprocess indicators to signals

Place inhopper

Activatemachine

Pick labelsfrom shelf

photos

Check glue tempis between 130 and 150 deg C

Record tempon control chart

If below 130 flushIf above 150 movedial up one notch

If in control leave aloneIf out of control, switchoff and tell supervisor

Place incontainer

Doing the work


Continuous Improvement


Seven Tools of Quality Flowcharts/maps

Pareto

Fishbone

Run diagram

Tally/histogram/measles

Correlation

SPC (Check sheets SOPs)

The seven

tools are a set !


“One of the greatest discoveries a man makes is to find he can do what he was afraid he couldn’t do.”

– Henry Ford

“One of the greatest discoveries a man makes is to find he can do what he was afraid he couldn’t do.”

– Henry Ford

“It’s kind of fun to do the impossible.”– Walt Disney

“It’s kind of fun to do the impossible.”– Walt Disney

“It’s not necessary to change. Survival is not mandatory.”

– W. Edwards Deming

“It’s not necessary to change. Survival is not mandatory.”

– W. Edwards Deming

Why Lean?


QUESTIONS ?


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