exercise lean feb 27 2010
DESCRIPTION
TRANSCRIPT
•We ensure that all Exercise Lean Professionals are We ensure that all Exercise Lean Professionals are hands–on and only operate with their “Boots to the hands–on and only operate with their “Boots to the Ground”.Ground”.
•We go to the “Gemba” and Transform the culture where We go to the “Gemba” and Transform the culture where the work is done.the work is done.
•We rely on the team developed Value Stream Map (VSM) We rely on the team developed Value Stream Map (VSM) of the entire process to identify The 8 Forms of Waste and of the entire process to identify The 8 Forms of Waste and set priorities.set priorities.
•We insist on solving problems when and where they occur We insist on solving problems when and where they occur using Standardized Toolsusing Standardized Tools
•We empower leaders to ensure Team Ownership and We empower leaders to ensure Team Ownership and sustainable resultssustainable results
4
•Rapid Assessment•Key Performance Indicators
Assess the Current State
•Rapid Assessment•Key Performance Indicators
Assess the Current State
•Lean Principles to the Workforce
•Empowering Leadership Training
Prepare for Improveme
nt
•Rapid Assessment•Key Performance Indicators
Assess the Current State
•Lean Principles to the Workforce
•Empowering Leadership Training
Prepare for Improveme
nt•Key Performance Indicator Objectives
•Priorities Established•Value Stream Mapping
Define the Future State
ProductionControl
Supplier Customer
MonthlyForecast
MonthlyForecast
WeeklyOrders
WeeklyOrders
Weekly
Daily Daily Daily Daily Daily
ProductionSupervisorWeekly
I
I
I
2500
Machine
(-4) 3360(-6) 1680
5 dy45 sec
10 dy 7 dy
3500
1 1 1
I nspect Package
4 dy30 sec
4 dy10 sec
I2000 2000
I
I 2000
Ship
4 dy
Daily
40 sec
1
Hone
5 sec
Cln/Deburr
10,080 pcs/month(-4) 6,720(-6) 3,360
504 pcs/ day(-4) 336 pcs/ day(-6) 168 pcs/ day
12 containers/ day
1Shif t/ Day (8.5 hrs)0.5 hr (Lunch)0.5 hrs (Breaks)
Available Time=460 min/ dy
CT=44 secC/O=60 minLot=1000 pcAvail=27,600Uptime=87%
CT=40 secC/O=5 minLot=1000 pcAvail=27,600Uptime=99%
CT=5 secC/O=0.0 minLot=1000 pcAvail=27,600Uptime=80%
CT=30 secC/O=5 minLot=1000 pcAvail=27,600Uptime=99%
CT=10 secC/O=5 minLot=1000 pcAvail=27,600Uptime=99%
Lead Time=34 dayTotal Cycle Time=130 secTotal Work Time=130 sec
P
Supplier Customer
ProductionControl
TwiceWeekly
Daily FAX/ PHDispatch
3-MonthForecast
Monthly BlanketOrder
3-Month ForecastUpdated Monthly
Ship
504 pcs/ day24 pcs/ container
(3)
Machine/Hone/ClnDeburr/ I nsp/ Pkge
CT=44 secC/O=20 minLot=500 pcAvail=27,600Uptime=87%
MonthlyBlanket Order
DailyDesignWorkcell
P
DesignKanban
DesignKanban
0.5 dy 2.5130 sec 1.5 dy 0.5 dy
1Shif t/ Day (8.5 hrs)0.5 hr (Lunch)0.5 hrs (Breaks)
Available Time=460 min/ dy
FAX TwiceWeekly Visual
Bottleneck=Machining
Takt Time=460min/504pcs=0.91min=55 sec
Lead Time=5.0 dyTotal Work Time=130 secCycle time=44 sec85% LT Reduction25%+Labor Reduction
Lot Size/ SetupTry for Lot=250
•Rapid Assessment•Key Performance Indicators
Assess the Current State
•Lean Principles to the Workforce
•Empowering Leadership Training
Prepare for Improveme
nt•Key Process Indicator Objectives
•Priorities Established
•Value Stream MappingDefine the
Future State
•“Boots to the Ground”
•Lean Tools•Leader Development
Remove Waste
•Rapid Assessment•Key Performance Indicators
Assess the Current State
•Lean Principles to the Workforce
•Empowering Leadership Training
Prepare for Improveme
nt•Key Process Indicator Objectives
•Priorities Established
•Value Stream MappingDefine the
Future State
•“Boots to the Ground”
•Lean Tools•Leader Development
Remove Waste
• Improvement Monitoring (KPIs/Action Plans)
• Leader Ownership• Sustained Results
Create Value
