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  • 1. Lean in Process Industries
  • 2. What You’ll Learn about Lean
      • What is Lean?
      • Key Lean Principles
        • Seven Wastes
        • Five Ss
      • Examples of Lean
        • Tool room
        • Maintenance shop floor
        • Lean process
        • Lean supply chain
      • Additional Resources
  • 3. What is Lean?
    • Umbrella term from the book "The Machine that Changed the World"
    •  Refers to practices and insights obtained from observers of the Toyota Production System during 1990s and early 2000s
    •  Lean and Six Sigma are related due to their emphasis on a formal evidence based approach to process improvement
  • 4. The Real Truth about Lean
    • Using and implementing Lean alone can not overcome poor management or business model or strategy 
    • Lean can improve execution by:
      • Reducing waste
      • Improving quality
      • Increasing profits
    • Lean can make you and your customer happier
    • Lean does require a long term commitment to sustain results 
    • Lean is a culture
    • Lean is not the end itself – it should be complicated!
  • 5. The 3Ms of Lean
    • Muri
      • Poor planning / unrealistic expectations
    • Mura
      • Poor process design
    •   Muda
      • After the fact performance gap due to muri and mura
  • 6. The 7 Wastes of Lean
    • Over production
      • Producing more material than is needed before it is needed is the fundamental waste in lean manufacturing--Material stops flowing.
    • Producing defective products
      • Defective products impede flow and lead to wasteful handling, time, and effort.
    • Inventories
      • Material sits taking up space, costing money, and potentially being damaged. Problems are not visible.
    • Motion
      • Any motion that does not add value to the product is waste.
    • Processing
      • Extra processing not essential to value-added from the customer point of view is waste.
    • Transportation
      • Moving material does not enhance the value of the product to the customer.
    • Waiting
      • Material waiting is not material flowing through value-added operations.
  • 7. The Five Ss of Lean
    • Sort
      • Sort needed and unneeded items.
    • Set in order
      • Put things in proper place and arrange.
    • Shine
      • Clean up the workplace.
    • Standardize
      • Standardize the first three S’s.
    • Sustain
      • Make 5S a part of the job.