cait@dozuki.com | @CaitEmmaSmith
Director of Outreach
Dozuki
Cait Emma Smith

Karen Bangs
Faculty Member
California Polytechnic State University
krbangs@calpoly.edu | 805-756-6210

Cal Poly University’s
Lean Systems 101

Workshop Roadmap
Cal Poly University’s Lean Systems 101
• Defining “The Goal”
• “The House of Lean Tools”
• Types of waste
• Cal Poly’s Basic Elements
• Quality at the Source
• Benefits of Lean Production
• 5S and Visual Management
• Additional Resources
• Audience Q&A

Cal Poly University’s Lean Systems 101
THE GOAL: VALUE
Respect for
People
Continuous
Improvement
FOUNDATION: MANAGEMENT SUPPORT
Product
Development
Flow

Cal Poly University’s Lean Systems 101
But how can you experience continuous improvement?
Eliminating waste.

Cal Poly University’s Lean Systems 101
CUSTOMER SATISFACTION
BUSINESS SUCCESS
RESPECT FOR PEOPLE
Team Building
Empowerment
Cross Training
Hoshin
Supplier Relationships
JIT
Pull
Flow
TAKT Time
Heijunka
Cell Design
SMED
JIDOKA
Poka-yoke
And on
Autonomation
5 Ways
Line Stops
Built in Quality
STABILITY & STANDARDIZATION

Cal Poly University’s Lean Systems 101
1. Finished Goods
2. Waiting
3. Transporting
4. Over Processing
Types of Waste
5. Factory Inventory
6. Movement
7. Defects
8. Talent

Cal Poly University’s Lean Systems 101
Types of Waste:
1. Finished Goods, 2. Waiting, 3. Transporting

Cal Poly University’s Lean Systems 101
Types of Waste:
4. Over Processing, 5. Factory Inventory

Cal Poly University’s Lean Systems 101
Types of Waste:
6. Motion, 7. Defects, and 8. Talent

Cal Poly University’s Lean Systems 101
Basic Elements
1. Flexible resources*
2. Celluar layouts*
3. Pull production system
4. Kanban production
5. Small lot production
6.Quick setups
7. Uniform production levels
8. Quality at the source*
9. Total productive maintenance
10. Supplier networks

Cal Poly University’s Lean Systems 101
Flexible Resources and Cellular Layouts
• Multifunctional resources
• Manufacturing cells

Cal Poly University’s Lean Systems 101
Multifunctional resources:
cross trained workers, general purpose
machines and equipment, and
common raw materials
Resources
Webinars
In-houseE-courses

Cal Poly University’s Lean Systems 101
Manufacturing cells: product layout and TAKT Time
BEFORE AFTER
A
B
C
A
B
C

Cal Poly University’s Lean Systems 101
Quality at the Source | Visual Control

Quality at the Source | Poka-Yokes
Cal Poly University’s Lean Systems 101

Cal Poly University’s Lean Systems 101
Basic Elements In Review
1. Flexible resources
2. Celluar layouts
3. Pull production system
4. Kanban production
5. Small lot production
6.Quick setups
7. Uniform production levels
8. Quality at the source
9. Total productive maintenance
10. Supplier networks

Benefits of Lean Production
Cal Poly University’s Lean Systems 101
• Reduced inventory
• Improved quality
• Lower costs
• Reduced space requirements
• Shorter lead time
• Increased productivity
• Greater flexibility
• Better relationships with suppliers
• Simplified scheduling and control activities
• Increased capacity
• Better use of human resources
• More product variety

5S and Visual Management
Cal Poly University’s Lean Systems 101

Cal Poly University’s Lean Systems 101
5S Scan:
Seiri (sort)
Goal:
Keep only what you need
Eliminate or correct:
Unneeded equipment, tools, furniture; unneeded items on walls,
bulletins; items blocking aisles or stacked in corners; unneeded
inventory, supplies, parts; safety hazards

Cal Poly University’s Lean Systems 101
5S Scan:
Seiton (set in order)
Goal:
A place for everything and everything in its place
Eliminate or correct:
Items not in their correct places; correct places not obvious; aisles,
workstations, and equipment locations not indicated items not put
away immediately after use

Cal Poly University’s Lean Systems 101
5S Scan:
Seisou (shine)
Goal:
Cleaning and looking for ways to keep clean and organized.
Eliminate or correct:
Floors, walls, stairs, equipment, and surfaces; cleaning materials
not easily accessible, labels, signs broken or unclean; other
cleaning problems

Cal Poly University’s Lean Systems 101
5S Scan:
Seiketsu (standardize)
Goal:
Maintaining and monitoring the first three categories
Eliminate or correct:
Necessary information not visible; standards not known; checklists
missing; quantities and limits not easily recognizable; items can’t be
located within 30 seconds

Cal Poly University’s Lean Systems 101
5S Scan:
Shisuke (sustain)
Goal:
Sticking to the rules
Eliminate or correct:
Number of workers without 5S training; number of daily 5S
inspections not performed; number of personal items not stored;
number of times job aids not available or up-to-date

Cal Poly University’s Lean Systems 101
Additional Resources
• Gemba Academy
• Google
• Institute of Industrial Engineers
• Central Coast Lean
• “The Toyota Way” by Jeffrey Liker

Cal Poly University’s Lean Systems 101
Audience Q&A

LinkedIn: Dozuki
Twitter: @Dozuki
Forum: dozuki.com/Answers/Ask/Lean_Systems
Cal Poly University’s Lean Systems 101
Continue the Conversation

Cal Poly University’s Lean Systems 101
cait@dozuki.com
@CaitEmmaSmith
Director of Outreach
Dozuki
Cait Emma Smith
krbangs@calpoly.edu
805-756-6210
Faculty Member
California Polytechnic State University
Karen Bangs
Thanks for joining us today!