free lean workshop march 2 2010 - sai global presentation...•discuss roadblocks •production...

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©SAI GlobalAll Rights Reserved XXXXXXXX-XXXX File Name.ppt p1

Welcome to SAI GlobalWelcome to SAI Global

Lean Initiative

SAI Global Improvement Solutions1 300 650 262www.saiglobal.comDonna M DiPalmaMobile: [email protected]

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What is Lean?

Lean is the systematic, continuous elimination of wasteful activities from processes, manufacturing, service or administrative.Lean is Cross Functional & All Inclusive!!!

“A process is a process”

•We need to be relentless in our pursuit of waste

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”Lean” is NOT about manufacturing –it is about

PROCESSES!!!!

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Waste – VA vs NVA

VA – Value add– A value added activity changes the product or

service in fit form or function

NVA – Non Value add– A non-value added activity does not change the

product or service

Waste - ????????

VE – Value Enabling – Inspection; Regulatory Requirements

VA- something customer willing to pay forNWA-does not add valueWaste!VE-Explain•Overproduction-creating inventory•Waiting-for anything-people-material-information-machines•Motion-movement of people, material paper, searching for tools, supplies, computer files•Transportation-movement of any work that does not add value ie: inefficient layout, excessive filing•Overprocessing-extra work customer not willing to pay for•Inventory- takes up space, $$, can become obsolete•Defects- rework, scrap•Resources-underutilization or improper utilization of people- no X-training

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GROUP ACTIVITY

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Lean Basics

Process MappingWaste eliminationMistake-proofing-poke yokeKanbanVisual ManagementTAKT time% Loading1 pc flowTreat root cause, “Not Symptoms”5SSet-Up reductionLean measurementTeamwork

Process Mapping-as is by observationWaste elimination-seek out and eliminate 5 whysMistake-proofing-poke yoke-powerpoints and petrol nozzlesKanbanVisual Management-ability to control info about product or service by visuals, signs postersTAKT time-The time you have1 pc flowTreat root cause, “Not Symptoms”get to the origin or source of problem5SSet-Up reductionLean measurementTeamwork-very powerful-energy

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What do we measure?

Lead timesCycle timesError rateTravel distanceSpace (Footprint)HandoffsAuthorizations

Waiting timeMachine down timeResourcesCustomer SatisfactionCustomer complaintsInventoryCarrying costsSpeed to market

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A good beginning….5S

Do the simple things right!

A starting point for any improvement activity

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5S

ScroungeStealStashScrambleSearch

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5S’s

SortSetShine (sweep)Standardize SustainSafety-6S

SeiriSeitonSeisoSeiketsuShitsuke

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Changing the“Culture”

The key to sustaining

•Mindset & behavior•Discuss roadblocks

•Production workers•Office/administrative staff•Middle management

•Sometimes see it as a threat•Sometimes can be territorial

•Culture cannot be changed by just communication & education•This change is realized by practicing & environment•Empowerment of “just do it” attitude

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Core Concepts

The right process will produce the right

results

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Philosophy as a foundation

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Add value to your organization by

developing your people

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ContinuouslyIdentify root cause and

Drive organisationallearning

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By implementing a lean strategy, a company can…..

Reduce costsReduce cycle timeReduce inventoryReduce work-in-process (WIP)Increase capacityImprove lead timesIncrease productivityImprove quality-increase profits

Reduce authorizationsReduce handoffsReduce waiting in in-basketsReduce time to service customerReduce tender response timeReduce bureaucracyReduce paper trailReduce quantity of forms

Fulfil their requirement for CI

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Where do we go FromHere?

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Identify areas of opportunityDecide on area to beginShould be very visibleLean is rapid, quick processHome runs are great!!

butLets begin with Quick wins– Incremental improvements

Low hanging fruit

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5SAwareness & training session for managementAssessment & 2 day blitz – assessment, process redesign and timeline for implementationRepetitive 5 day Lean events – includes 6 hour training and implementation of new processCoachingMentoringGoal – build your internal capabilities!!!

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Affinity diagram results

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Questions&

Answers

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Special offer to attendees

Free 1 hour introductory discussion with your management and decision makers.

Booking needs to be made by March 12 2010 for delivery at a later date

Limited basis depending upon availability

free lean workshop march 2 2010 - sai global presentation...•discuss roadblocks •production...

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