29 introduction to lean manufacturing
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©ABSLPowerSolutions2007©STMQualityLimited
STM QualityLimited
Introduction toLean Manufacturing
TOTAL QUALITY MANAGEMENT
Lean Manufacturing
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©STMQualityLimited
STM QualityLimitedefinition of Lean Manufacturing
“Theproductionofgoodsusinglessof
everythingbyreducing„waste‟andincreasing
valueaddedactivity”
If it doesn‟t add value, it adds cost!
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©STMQualityLimited
STM QualityLimitedreparing for Lean Manufacturing
FiveLeanPrinciples
Specify ValueIdentifywhatthe
customeractuallywants
•Wouldyoupayfor
somethingyoudidn‟t
want?
•Ifit‟snotaddingvalue,it‟saddingcost!
Identify the
Value Stream
Identifythewholeprocess
(mapping)•Whatarethefactsabout
ourprocesscapability?
•What„waste‟istherein
theprocess?Make product
flow
•Eliminatebottlenecksor
managethembetter
•Reduceoravoid„batch&
queue‟
•Getthemaintenanceright
Let the
customer pull Onlymakewhatthecustomerrequires,when
thecustomerwantsit.
ContinuousImprovement
Increasingpersonal&
companyknowledgeto
pursuethecomplete
eliminationofwaste.
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STM QualityLimitedreparing for Lean Manufacturing
Reduction&eliminationof„waste‟elementsintheprocess
Equipmentreliability – PlannedPreventativeMaintenance(P.P.M.)
AutonomousMaintenance&ConditionMonitoring
Continuousflow-onepartatatime(JIT)&pull„Kanban‟systems
Inventory(WIP)reductionthroughouttheprocess
Defectreduction-rightfirsttime,errorproofing&training
Visualmanagement – simplemeasures(KPI‟s)&drumbeat
Quickmachinechangeovers(SMED)
Teamwork&communication
Pointofusestoragebutnot„nests‟
Bottleneckmanagement
Sowhatdoes„best‟looklike?
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STM QualityLimitedreparing for Lean Manufacturing
Disorganised
Organised
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©STMQualityLimited
STM QualityLimitedrocess Mapping
Aprocessis…
Asetofactivitieswhichconvertinputstooutputsto
meetagreedcustomerrequirements.
“Drawaflowchartofwhatyoudo.Untilyoudo,youdo
notfullyunderstandwhatyouaredoing,youjusthave
ajob”
DrW.E.Deming
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STM QualityLimitedrocess Mapping
Characteristicsofanidealprocess…
– Eachstepaddsvalue
– Eachstepiscarriedoutonlyonce
– Stepsarecarriedoutinthebestsequence
– Usestheoptimumlevelofresource
– Meetscustomerneedsconsistently
– Minimumspacerequirements
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STM QualityLimitedhy Process Map?
Biggesttoolinlean – allothersaredeployedfrommapping
output
Bigpicture – detailcomeslater
Establishesrealprioritiesbythosewhodothework – action
planswithnames&dates
Dramaticshort&medium-termresults
Ideageneration&teaminvolvementindecisionmaking
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STM QualityLimitedrocess Atlas
Customerneeds CORE PROCESSES SatisfiedCustomer
KPI’s
MANAGEMENT PROCESSES
STRATEGY
DATA
SUPPORT PROCESSES
RESOURCES
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STM QualityLimitedoundaries and Scope
Starttofinish…orderenquirytoreceiptofpaymentortighter
definitionwecaninfluence?
Allpossibleproductsor„runners‟only?Thinkflow&volume
Whatfunctionsdoweneedinvolvedbeyondthisroomboth
internal&external?
Isthereanobviousneedformoreinformationatthisstage?
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STM QualityLimitedean Wastes
The„8LeanWastes‟(7+1)
Introductionto„TIMWOODS‟
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STM QualityLimitedIM WOODS
T – Transport
I – Inventory
M – Movement
W – Waiting
O – Over-processing
O – Over-production
D - Defects
S - Skill