lean tools and resulting roi 2015
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Introduction to Lean
Presented toProfitability in Manufacturing MEP
By Bill Bearnson
What is Lean Manufacturing?
Identifying what the customer wants in form fit and function of a product. What the customer is willing to pay for. Anything else is waste.
Systemic removal of any activity that does not add value to the form fit or function. This is waste.
A systemic process to improving flow of a product focusing on what adds value and the customer will pay for.
What is Lean Manufacturing?
A commitment to manufacturing culture change.
• The most noteworthy accomplishments in keeping the price down low is the gradual shortening of production cycles. Henry Ford
• It encompasses the successful execution of all manufacturing activities required to produce a final product, from design engineering to delivery and including all stages of conversion from raw material onward. Dr. Shingo Shigeo
Common Wastes1. Transport (moving products that are not actually required to perform the
processing). Example: inspection stations instead of “in process inspections”.
2. Inventory (all components, work in process, and finished product not being processed). Example: Component failures not accounted for and reported in supplier rating.
3. Motion (people or equipment moving or walking more than is required to perform the processing). Example solution: equipment repair done in test lab.
4. Waiting (waiting for the next production step, interruptions of production during shift change). Example: Setup and tear down time due to parts missing or cross training.
5. Overproduction (production ahead of demand). Example: Fast food.
6. Over Processing (resulting from poor tool or product design creating activity). Example: Design for manufacturing is missed. Test till it passes.
7. Defects (the effort involved in inspecting for and fixing defects). Example: manufacturing assets being used for evaluating returned product revisions and failures
Some Lean Tools
• Five S, Kanban (pull systems)• Value Stream Mapping: Kaizan event• Redesigning working cells. Reducing
movement.• Continuing improvements. • single point scheduling. Master scheduler.
What is 5S?
The results you can expect from a Five S program are: improved profitability, efficiency, service and safety. A great place to start Lean effort
What’s a Kanban and will they hurt me?
Kanban aligns inventory levels with actual consumption.
Toyota optimized its engineering process by modeling it after supermarkets stock shelves. Or, Just in time.
Value Stream MapCentral Control.
Critical Design Review
Lean ToolsProcess Flow Diagram
Engineering Design Effort
Purchase long lead parts
Preliminary Design, PL and DWG Review
Design Released
Long lead parts identified for management review.
Release long lead P/L , preliminary
drawing and prelim full P/L
Parts being received hold rack
Cycled until full kit ready
MFG and Test/Eval & Processing per priorities
Manufacturing Processes document begun and complete
Parts and Processes dropped to manufacture floor for build and test.
Customer Requirements
Buy LLP Decision is a GO!!
Buy LLP Risk Decision is Yes
TEST , MFG and MFG MNGT
begines involvement
RISK
Flow diagramming Benefits1. Bring Team together 2. Team agrees on Risks and mitigation
actions3. Cross functional review early by all
stake holders. 4. Better use of manufacturing assets.
Summary
Lean is:A commitment to
manufacturing culture change.
Lean Return on Investment:1. Improved manufacturing
efficiency. 2. Quicker Delivery3. On target customer wants
and needs they will pay for.
4. Lower Cost Product.5. Company staff retention
and moral.
Support
Lean Engineering Tools
The product design is not just based on good design but it should be possible to produce by manufacturing as well.
1. Design for Manufacturability2. Robust Design with variation control
Lean Engineering Tools
Robust Design by variation control.
Robust parameter designs used to make visula the interaction between control and uncontrollable variables by robust design.
Once optimal control factors are implemented, it is ready for production and delivery.
Robust DesignExample: resistor pack reduction concept
Value RFresistors
Variable 10k-12kRP
Gain output dBm
Spec’d Circuit Gain
.5k 10-12k 20-24dB 3-4dB1k 10k-12k 7-10dB 3-4dB2k 10k-12k 5-6dB 3-4dB3k 10k-12k 3dB-4dB 3-4dB4k 10k-12k 2-3dB 3-4dB5k 10k-12k 2-2.4dB 3-4dB
10k 10k-12k .01-2dB 3-4dB
400 – 400KHz
Lean Engineering Tools
-- Design for manufacturing (DFM)1. Simplify parts list where possible.2. Specify parts for use, environment and possible
future environments.3. Record risks taken in prototype stage for addressing
in first time build.– Unavailable parts that will make the sell but don’t meet
specification completion.– Parts that may impede manufacturing and test flow. Note
the risk and known mitigation.4. Review for first time build and low rate build with
MFG, Design, build technicians, process and Test.
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