introduction to lean manufacturing
DESCRIPTION
Lean manufacturingTRANSCRIPT
© ABSL Power Solutions 2007© STM Quality Limited
STM Quality LimitedIntroduction to
Lean Manufacturing
TOTAL QUALITY MANAGEMENT
Lean Manufacturing
© STM Quality Limited
STM Quality Limited
Definition of Lean Manufacturing
“The production of goods using less of everything by reducing ‘waste’ and
increasing value added activity”
If it doesn’t add value, it adds cost!
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STM Quality Limited
Preparing for Lean Manufacturing
Five Lean Principles
Specify Value
Identify what the customer actually wants• Would you pay for something you didn’t want?• If it’s not adding value, it’s adding cost!
Identify theValue Stream
Identify the whole process (mapping) • What are the facts about our process capability?• What ‘waste’ is there in the process?
Make productflow
• Eliminate bottlenecks or manage them better • Reduce or avoid ‘batch & queue’• Get the maintenance right
Let the customer pull
Only make what the customer requires, when the customer wants it.
ContinuousImprovement
Increasing personal & company knowledge to pursue the complete elimination of waste.
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STM Quality Limited
Preparing for Lean Manufacturing
Reduction & elimination of ‘waste’ elements in the process Equipment reliability – Planned Preventative Maintenance (P.P.M.) Autonomous Maintenance & Condition Monitoring Continuous flow - one part at a time (JIT) & pull ‘Kanban’ systems Inventory (WIP) reduction throughout the process Defect reduction - right first time, error proofing & training Visual management – simple measures (KPI’s) & drumbeat Quick machine changeovers (SMED) Teamwork & communication Point of use storage but not ‘nests’ Bottleneck management
So what does ‘best’ look like?
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STM Quality Limited
Preparing for Lean Manufacturing
Disorganised Organised
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Process Mapping
A process is…
A set of activities which convert inputs to outputs to meet agreed customer requirements.
“Draw a flow chart of what you do. Until you do, you do not fully understand what you are doing, you just have a job”
Dr W.E.Deming
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STM Quality Limited
Process Mapping
Characteristics of an ideal process…
– Each step adds value
– Each step is carried out only once
– Steps are carried out in the best sequence
– Uses the optimum level of resource
– Meets customer needs consistently
– Minimum space requirements
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Why Process Map?
Biggest tool in lean – all others are deployed from mapping output
Big picture – detail comes later
Establishes real priorities by those who do the work – action plans with names & dates
Dramatic short & medium-term results
Idea generation & team involvement in decision making
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Process Atlas
Customer needs CORE PROCESSES Satisfied Customer
KPI’s
MANAGEMENT PROCESSES
STRATEGY
DATA
SUPPORT PROCESSES
RESOURCES
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Boundaries and Scope
Start to finish… order enquiry to receipt of payment or tighter definition we can influence?
All possible products or ‘runners’ only? Think flow & volume
What functions do we need involved beyond this room both internal & external?
Is there an obvious need for more information at this stage?
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STM Quality Limited
Lean Wastes
The ‘8 Lean Wastes’ (7 + 1)
Introduction to ‘TIM WOODS’
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STM Quality Limited
TIM WOODS
T – Transport
I – Inventory
M – Movement
W – Waiting
O – Over-processing
O – Over-production
D - Defects
S - Skill