Basics of Leanfor Manufacturing

On-Demand, Defect-Free,

One-By-One at the Lowest Cost

Perception of Lean

What do you see?

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Why Are We Really Here??Why Are We Really Here??

• Quality product for the Quality product for the

war fighterwar fighter

• Grow our businessGrow our business

• Keep existing businessKeep existing business

• Be competitiveBe competitive

• Make your job easierMake your job easier

• Eliminate process wasteEliminate process waste

• Balance the workloadBalance the workload

• Reduce operator burdenReduce operator burden

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Who is effected by our costs?

Everyone from Soldiers to children are effected by the cost to manufacture our vehicleEveryone from Soldiers to children are effected by the cost to manufacture our vehicle•Children Children •War fightersWar fighters•TaxpayersTaxpayers•Business ownersBusiness owners•Virtually Everyone Virtually Everyone

Training Objectives

Define Lean Understand Value and Waste Standard Work One Piece Flow Pull Systems 6S RIE Cycle

What is Lean?

Lean is the identification and elimination of waste

Remember Lean is a process for identifying and eliminating waste with the goal of creating Value

Reasons For Lean

4 Core tools of Lean

4 key tools: Standard Work 1 Piece Flow Pull Systems 6s

and (for all tools)... VISUAL MANAGEMENT

11

66 SS

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Standard Work

Takt Time is the Pulse or Heartbeat of the Plant Takt Time= Available Work Time / Customer Demand

Standard Work Developed by the operators Repeatable sequence of work operations

Standard Worksheets Provides adherence to standard work in the area Used to train operators Displays the sequence of steps for the operators

One Piece Flow

The movement of a product through the process one unit at a time

The opposite of Batching

Reduces: Wait time Lead time WIP

10 Benefits of One Piece Flow

Improved Safety Builds in Quality Improves Flexibility Improves Scalability Reduces Inventory Improves Productivity Simplifies Material Replenishment Frees Up Floor Space Makes Lean Take Root Improves Moral

Pull Systems

Pull Systems - Example

Pull Systems

Lego Exercise

What is 6S ?

6S- A methodology for organizing, cleaning, developing, and sustaining a work environment.

This lean manufacturing tool is referred to as “6S” due to the six steps, all beginning with the letter “S”.

6-S Objectives

Establish area based teams with clear responsibilities and boundaries.

Standardize practices within the work area and across the site.

Introduce the practice of area based teams and self audits.

Improve safety, productivity, and moral by establishing “a place for everything and everything in it’s place” within the work area.

Benefits of 6S

An organized, efficient workplace for improved productivity.

A cleaner work place for improved safety. Reduced inventory and supply costs. Recapturing valuable floor space and

minimizing overhead costs. Improve “how we feel” about our product,

our company, and ourselves. Provide an “always-ready” customer

showcase to promote our business.

Elements of 6S

Sort - what is not needed, sort through, then sort out; “When in doubt, move it out!”

Set in Order - straighten what must be kept; make it visible and self-explanatory so everyone knows what goes where.

Shine - everything that remains. Clean and inspect equipment, tools and workplace.

Standardize - the clean routine. Make it more automatic.

Sustain - requires self discipline, stick to the rules and make them a habit.

Safety – improve area safety issues and sustain safe practices.

When to do 6S

Space is crowded with parts and tools. Unneeded items are stacked between and

around workers. Excess inventory on the floor. Excess items and machines make it difficult

to improve process flow. Equipment is dirty and a collection point for

miscellaneous materials. Needed equipment such as tools are difficult

to find.

The 8 Wastes

Training Exercise: Stop and Identify at least one waste for each category

INJURIES DEFECTS INVENTORY OVERPRODUCTION WAITING TIME MOTION TRANSPORTATION PROCESSING WASTE

Sea of Waste

“value-adding” changes the fit form or function of the product

DRILLING ASSEMBLING PAINTING CUTTING

Value Adding

Non-Value Adding “non-value adding” consumes time and money

...but does not change the fit form or function of the product

SORTING COUNTING STACKING EXPEDITING CHECKING WALKING

R.I. Events – A 7-Week Cycle

3 weeks preparation: topics, teams, targets

5 days of rapid, focused, team action: DAY 1: STUDY CURRENT CONDITIONS DAY 2: IMPLEMENT MAJOR CHANGES DAY 3: TRY OUT AND DEBUG DAY 4: STANDARD WORK (and redeploy) DAY 5: PRESENTATION (results and recognition)

3 weeks follow-up: all or nothing, solve, sustain

Value and Non Value Exercise

Use the 4 core tools of lean to identify and eliminate waste in the “Toast” Process.

Identify waste / Review current process Remove waste / set up target process Trial process and look for additional

improvements Reflect on what has been learned

Toast

Test

15 Minutes 21 Multiple Questions Covers items in this training Good Luck