Step wise approach of implementing lean manufacturing ... only do that activity where customer is willing to pay .... other then this it should be eliminated or reduced through implementation of Lean manufacturing

1. LEAN IMPLEMENATION
Step wise Approach …..
By
ABHIJIT SHINDE

2. Step 1 …….
SR No Lean Tool Application /Activity Scope
1 3 ‘S 1.Sorting activity
2.Red Bin Activity
3. 1S Red tag activity ..
4.Preparation of 1S and 2S Sorting Register ,
5.Identification of storage Method …
6.Identification of action on item as per uses ..
7.PEEP(Place for everything and every on its
place ) for all the material present in the work
station
Overall plant , zone wise
2 Visual Controls and
Management
(Aandan )
1.Identification of visual control opportunity on
the work station .
2.Eastablish the visual control to getting the
information of static and dynamic movement of
machine and surroundings
Selected machine , zone,
Or area of the plant
3 4S and 5 S 1.Prepartion of 5S Check sheet
2. 2 Level audit establishment for sustenance of
3S .
All 5 S Zone

3. Step 2 …….
SR No Lean Tool Application Scope
1 Gemba Kaizen 1.Identifiaction of opportunity for the Genba
kaizen .
2.Identification and quick implementation of
kaizen ..
3.Focus in “Total Employee Involvement “
4. Understanding and awareness of basic kaizen
concept
5.Impleneation of Idea and suggestion scheme
from operator
Overall plant , zone wise
, section wise , line wise
2 Error Proofing 1.Identifiaction of opportunity for the error
proofing
2.Identification of multiple solution..
3.Implenation of solution
Entire plant , zone wise ,
section wise , line wise

4. Step 3…….
SR No Lean Tool Application Scope
1 16 Losses and 7
waste identification
1.Data collocation and identification of 16 losses
and 7 waste ..
2.OEE Calculation and Capturing of losses
obtained from the OEE ..
3.Prepare the Loss Vs Cost Matrix Table
4. Prioritization of the losses based on the data
Overall plant , zone wise
, section wise , line wise
2 Establishment of
objectives (Result
Indicators )
1.Based on the policy of the organization
,establish the result indicators of lean
implantation based on PQCDSM
Overall Plant
3. Kaizen Blitz 1.Identification of the teams based on category
of kaizen blitz
2.Identification of kaizen blitz time zone
Selected zone

5. Step 4…….
SR No Lean Tool /Steps Application Scope
1 Project selection
and Prioritization
1.Based on the data collocation , Prioritize the
losses and waste
2.Identify the team as per losses
3. Team charter sign off
Project wise
2 SMED 1.Implenation of SMED Tool (Signal Minute
exchanging the die ) in the set up area .
2.Identifcation of online and offline activity
Set up area and machine
3. Line Balancing 1.Identification of bottleneck process and
machine
2.Implemenation of line balancing principal
Project wise
4. ECRS (Elimination ,
Combination
replacement
,simplification )
1.Based on the problem solation can be selected
based on ECRS Principal
Project wise

6. Step 5…….
SR No Lean Tool /Steps Application Scope
1 Level 1 VSM 1.Level 1 VSM (Value stream mapping for the
consideration of Customer , process , supplier
Overall Plant
2 Time study 1.Lead Time calculation
2.Through put time calculation
3.Talk Time Calculation
Plant wise
3 Flow study
(Information and
material )
1.Line stability calculation
2.Syncronization calculation
Plant wise
4. Inventory and
Motion study
1.Standard inventory calculation
2.Motion Calculation
3.VA/NVA Ratio Calculation
Plant wise

7. Step 6 …….
SR No Lean Tool steps Application Scope
1 Level 2 VSM 1.Level 2 VSM (Value stream mapping for the
consideration of Line , product and process
Overall Plant
2 KANBAN 1.Identification of path of material flow
2.Identification of stage of KANBAN
3.Preparation of KANBAN Card
3.Implenmation of KANBAN Principal
Selected Line and HD in
all line
3 Line Control
(Theory of constrain
)
1.Identification of the critical Lines
2.Identification of constraint of operation
3.Soluation identification
Selected Line
4. Standardized work WSS (Work station standardization ), Line activity
standardization
Selected Line

8. Step 7 …….
SR No Lean Tool steps Application Scope
1 Level 3 VSM 1.Level 1 VSM (Value stream mapping for the
consideration of Machine .
Selected Machine
2 TPM 1. Identification of the model machine
2. JH Implication of model machine as well as
HD in all machine
3.KK Implementation
4.PM Pillar Implementation
5.QM and E&T , SHE Implementation
Selected Machine
3 Judoka 1.Identify the opportunity for small automations
2.Identification possible solution for the
automations
Selected Machine
4. JIT 1.Implenmation of level production , schedule
production ,
2.Implemation of Just in Time Management
principal
Selected Machine

9. Thank You ….