Workshop A Performance Boosting Tools Reality Check: Are you a Lean, Mean Manufacturing Machine ?...
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Transcript of Workshop A Performance Boosting Tools Reality Check: Are you a Lean, Mean Manufacturing Machine ?...
Workshop AWorkshop A Performance Boosting ToolsPerformance Boosting Tools
Reality Check: Are you a Lean, Mean Manufacturing Machine ?
The Matrix: Performance Measurement System
Producing Profitability through Producing Profitability through Lean ManufacturingLean Manufacturing
What is Lean Manufacturing ?Why should I adopt Lean Manufacturing ?How can I apply Lean Manufacturing ?
Bus Info
FlowSix Sigma
SU TPM5s
Kaizan
Value-added
What is Lean Manufacturing?What is Lean Manufacturing?A long-term philosophy to propel a box
plant to higher profitabilityA business strategy that focuses on rapid
continuous low-cost improvement in processes and productivity
A tactical plan that integrates several tools into a complete package
A relentless attack on waste using a set of tried and true tools and techniques
Why adopt Lean Principals ?Why adopt Lean Principals ?
Increase capacity Reduce inventories Reduce Cycle Times / Lead times Lower space/facility requirements Lower overall costs Improve employee moral through increased
involvement Increase sales through focus on customer and
value-added activities
Where did Lean Manufacturing Where did Lean Manufacturing come from?come from?
Lean Techniques are Not New
James Womack & Daniel Jones– The Machine That Changed the World (1990)– Lean Thinking (1996)
Toyota Production System (1950’s – 1970’s)– JIT / Kanban / SU Reduction / SOP / 5s / Flow
Motorola (1986-1988)– Six Sigma / Variation Reduction / Process Capability
Major ConceptsMajor Concepts1. Waste
Seven types Overproduction Waiting Material Movement Excess Inventory Excess Motion Defects Unnecessary Processing / Converting
2. ValueThose things the customer wants and is willing to pay for.
3. Value Stream All activities required to design, order, produce and deliver a product
or service.
Goal of Lean ManufacturingGoal of Lean Manufacturing
Focusing on the value stream, identify those things that create value vs. those that do not and relentlessly attacking waste.
Major ToolsMajor Tools Value Stream Analysis
– Identify Value-added vs. non-value added activities Six Kaizan Events
– 5s Housekeeping
– Flow
– Set-up reduction
– TPM
– Defect/Variation Reduction
– Business Processes/Information
Value Stream MappingValue Stream Mapping
Identifying Value Added vs. Non-value added Activities
Product families = items/orders with a common process or machine routing
Target each product family for improvement efforts
Kaizen EventsKaizen EventsShort burst of intense activity and effort (3-5 days)Biased toward action over analysisConsist of multi-functional team assembled to
achieve a specific goal or solve a specific problemFocused on improving the value stream and
achieving flowManaged with daily reviews to resolutionGoal driven – Solving Problems and eliminating
waste
Kaizen Event # 1Kaizen Event # 1
5s+1 Housekeeping– Sort– Set in order– Shine– Standardize– Sustain– +1 = Safety
Kaizen Event # 2Kaizen Event # 2
Flow– material, people and activities
Macro Level and machine/dept level
Lean Tools:– Spaghetti Diagram– Flow Charts
Kaizen Event # 3Kaizen Event # 3
Set-up Reduction
Lean Tools:– “Pit Stop” Set-up mentality– Video Tape and Set-up Analysis– Internal vs. External SU activities
Kaizen Event # 4Kaizen Event # 4TPM = Total Productive Maintenance
Goal is to minimize downtime & maintain capability of equipment
Lean Tools:– Develop Daily Operator PM and Maintenance PM– Develop equipment critical spare parts list– 5s Program contributes toward TPM
Kaizen Event # 5Kaizen Event # 5
Defect / Variation Reduction– Six Sigma Tools
Pareto ChartsHistogramsProcess Mapping (KPIV, KPOV)Cause & Effect AnalysisFMEACapability Analysis
Kaizen Event # 6Kaizen Event # 6
Business Process / Information Flow– Design Process– Quotation– Order Entry– Manufacture Order– Shipping Order– Customer Feedback– Accounting / Administration
Keys to Successful Lean Keys to Successful Lean ManufacturingManufacturing
Education and CommunicationEmployee Involvement & empowermentCreate a culture tolerant of experimentation
- allow people to successfully make mistakesBreak the paradigm that Inventory is an AssetIncorporate Lean concepts into you culture
and ongoing strategic plan – not a “project”
Are you a Lean Mean Are you a Lean Mean Manufacturing Machine ?Manufacturing Machine ?