kblmt b000 intro kaizen based lean manufacturing
DESCRIPTION
Kaizen Based Lean ManufacturingTRANSCRIPT
Business Basics, LLC 6003 Dassia Way, Oceanside, CA 92056
West Coast: 760-945-5596Email: [email protected]
KAIZEN BASED LEAN MANUFACTURING
(KBLM)
0-1
Introduction
HOW TO INCREASE SPEED, IMPROVE QUALITY AND LOWER COSTS
Business Basics, LLC 6003 Dassia Way Oceanside, CA 92056 760-945-5596
MASTERING THE EIGHT-BASICS OF KAIZEN BASED LEAN MANUFACTURING
Copyright © 2006 Business Basics, LLC
All rights reserved. No part of this tutorial may be reproduced for any purpose other than the in-house training of employees
of companies that have purchased this tutorial.
0-2
MRP EVOLUTIONTo Much of a Good Thing ???
1950s COMPUTERIZED MRP
1970s CLOSED LOOP MRP (Manufacturing) Shop floor control Capacity Planning
1980s COMPUTRIZED MRPII (Finance) Cost accounting
1990s ERP (Engineering) Product Data Management (PDM) Computer Aided Design (CAD) Human Resource Management (HRM) Customer Relations Management CRM)
0-3
MATERIAL REQUIREMENTS PLANNING
The Balancing Act
Cancel Reorder
Reschedule
MASTER SCHEDULE
BILLS OF MATERIAL
LEADTIMES
LOT SIZES
INVENTORY
PURCHASEORDERS
WORK-IN-PROCESS
+_
REQUIREMENTS COVERAGE
0-4
The Planner/Buyer Challenge
GROSS REQUIREMENTS
SCHEDULED RECEIPTS
PROJECTED ON-HAND
NET REQUIREMENTS
PLANNED ORDER RECEIPT
ORDER RELEASE DATE
1 2 3 4 5 6 7 8
15 45154040 30
100
60 20 80 50 35 35 90
10
100
100
PERIODS
5 6 7 8 9 10 11 8 9 10 11 12 13 1 2 3
151540 15 301525 30
PERIODS
1 31 2
X Y
MASTER SCHEDULE FOR “1”PLANNED ORDERS FOR “X” PLANNED ORDERS FOR “Y”
LEAD TIME = 4 LEAD TIME = 6
PART “1”
ON-HAND 95 ALLOCATED 20 SAFETY STOCK 0 LEAD TIME 3 LOT SIZE 100
PERIODS
MATERIAL REQUIREMENTS PLANNING
0-5
-10
The reality of statistical probabilityTHE MRPII CRUSADE – What went wrong, Ollie?
COMPUTERGENERATED
MASTERSCHEDULE
COMPUTERGENERATEDMRP TAKE-ACTIONS
Master ScheduleSales Forecast
Production BOMSales Configurator
Prod’n Inventory
Purchase Orders
FG Inventory
Product Design
_____ %MASTER SCHEDULE
INTEGRITY _____ %ORDER-LAUNCHAND CONTROL
ACCURACY
___%___%
___%
___%
___%
___%
___%
___%
___%
___%
Order Entry Shop Orders
MATERIAL REQUIREMENTS PLANNING
0-6
World-Class Manufacturing Performance
MRPSHOP FLOOR
CONTROL SYSTEMS
0-7
REDUCE
COSTS
OPTIM IZE
"GEM BA" (Factory) PERFORM ANCE
EXCEED
BOTTOM -LINEEXPECTATIONS
INCREASE
SPEED IM PRO VE
QUALITY
INFO RM ATIO NINTEG RITY
CUSTO MER CO NNECTIVITY
BALANCEDSCO RECARD
Mastering the eight-basics of KBM that build a foundationfor MRP, ERP and lean manufacturing success
SEQ UENTIAL PRODUCTIO N
PO INT O FUSE
LO G ISTICS
CYCLETIM E
M GMT.
PRO DUCTIO N LINEARITY
RESO URCEPLANNING
#8.
#3.
#2.
#1.
#5.#4.
#7.
#6.
KAIZEN BASED M ANUFACTURING (KBM ) – W hat is it?
Kaizen is a set of quick-hitting, continuous improvement techniques that optimizes manu-facturing performance. Kaizen Based Manufacturing (KBM) establishes its eight-basics ofmanufacturing as the targets of kaizen. KBM provides a foundation for pursuing world classmanufacturing, achieving a lean enterprise and exceeding bottom line expectations.
0-8
FACTORY FLOOR REALITIES
MRPII/ERP
Order Launch & Expedite
Stockrooms
EOM Syndrome
Inside-of-lead-time Chaos
Functional Responsibility
Management Structures
Vendors as Adversaries
Vertical Integration
Annual Goal Setting
KBLM
Sequential Production
Point-of-use Logistics
Production Linearity
Schedule Flexibility & Agility
Process Ownership
Self Directed Teams
Supplier Partnerships
Non-core Outsourcing
Balanced Scorecard
0-9
KAIZEN BASED LEAN MANUFACTURING - KBLM EXPECTATIONS
CHANGE BENEFITS
Less direct supervision Increase in people creativity
Team empowerment Timely problem solving
Process ownership Built-in quality
Self-direction Enhanced performance
Direct communications Better decision-making
A “no status quo” mindset - schedule flexibility/agility - healthier profit margins
- higher inventory turns
Performance recognition Employee - job satisfaction - financial reward
Employer - people retention - financial reward
0-10
TYPICAL RESULTS: MRP + KBLM
0 10 20 30 40 50 60 70 80 90 100
MRPII or ERP KBLM
Purchasing Costs
Manufacturing Costs
Factory Space
Build/Test Cycle Times
Quality Costs
Inventories
Results Displayed as Range of Percent Reductions
%% REDUCTION
0-11
A CLIENT’S ACTUAL KBLM RESULTS
0123456789
Year 1 Year 2 Year 3
05
1015202530354045
Year 1 Year 2 Year 3
PRODUCT BUILD CYCLE( IN DAYS)
PROFIT MARGIN (IN %)
INVENTORY
(IN TURNS)
05
1015202530354045505560
Year 1 Year 2 Year 3
0-12
EIGHT MANUFACTURING BASICS THE TARGETS OF KAIZEN
1. Information Integrity
2. Motivational Measurement
3. Sequential Production
4. Point-of-Use Logistics
5. Cycle Time Management
6. Production Linearity
7. Resource Planning
8. Customer Connectivity
0-13Email: [email protected]
