Lean Process and Production

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Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods).
The Toyota Production System
All work shall be highly specified as to content, sequence, timing, and outcome
Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses
The pathway for every product and service must be simple and direct
Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization

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Lean Process and Production

  1. 1. Lean Production  Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods)  Lean Production also involves the elimination of waste in production effort  Lean Production also involves the timing of production resources (i.e., parts
  2. 2. Features of Lean Production • Management philosophy • “Pull” system though the plant WHAT IT IS • Employee participation • Industrial engineering/basics • Continuing improvement • Total quality control • Small lot sizes WHAT IT REQUIRES • Attacks waste • Exposes problems and bottlenecks • Achieves streamlined production WHAT IT DOES • Stable environment WHAT IT ASSUMES
  3. 3. Lean Six Sigma Incorporates the Key Methods, Tools, and Techniques of Its Predecessors
  4. 4. The Toyota Production System  Based on two philosophies: 1. Elimination of waste 2. Respect for people
  5. 5. Elimination of Waste 1. Focused factory networks 2. Group technology 3. Quality at the source 4. JIT production 5. Uniform plant loading 6. Kanban production control system 7. Minimized setup times
  6. 6. Respect for People Level payrolls Cooperative employee unions Subcontractor networks Bottom-round management style Quality circles (Small Group Involvement Activities or SGIA’s)
  7. 7. Toyota Production System’s Four Rules 1. All work shall be highly specified as to content, sequence, timing, and outcome 2. Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses 3. The pathway for every product and service must be simple and direct 4. Any improvement must be made in
  8. 8. Lean Implementation Requirements: Design Flow Process Link operations Balance workstation capacities Redesign layout for flow Emphasize preventive maintenance Reduce lot sizes Reduce setup/changeover time
  9. 9. Lean Implementation Requirements: Total Quality Control Worker responsibility Measure SQC Enforce compliance Fail-safe methods Automatic inspection
  10. 10. Lean Implementation Requirements: Stabilize Schedule  Level Schedule  Underutilized Capacity  Establish freeze windows
  11. 11. Lean Implementation Requirements: Kanban- Pull Demand pull Back flush Reduce lot sizes
  12. 12. Lean Implementation Requirements: Work with Vendors Reduce lead times Frequent deliveries Project usage requirements Quality expectations
  13. 13. Lean Implementation Requirements: Reduce Inventory More Look for other areas Stores Transit Carousels Conveyors
  14. 14. Lean Implementation Requirements: Improve Product Design Standard product configuration Standardize and reduce number of parts Process design with product design
  15. 15. Lean in Services (Examples) Organize Problem-Solving Groups Upgrade Housekeeping Upgrade Quality Clarify Process Flows Revise Equipment and Process Technologies
  16. 16. Lean in Services (Examples) Level the Facility Load Eliminate Unnecessary Activities Reorganize Physical Configuration Introduce Demand-Pull Scheduling Develop Supplier Networks
  17. 17. Thank You...

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