Lean 101 Lego Lean Orientation

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Lean 101 Lego Lean Orientation

  1. 1. <ul><li>Lean Overview – </li></ul><ul><li>The Basics…… </li></ul><ul><li>Presented By: Bill Stockstill – TMAC </li></ul><ul><li>Panel Members </li></ul><ul><li>Rosina Wittmeyer – DRS Infrared Technologies, LP </li></ul><ul><li>Bob Brunett – Bell Helicopter Textron </li></ul><ul><li>Mike Navaira – Lockheed Martin Aeronautics </li></ul>
  2. 2. <ul><li>Texas Manufacturing Assistance Center </li></ul><ul><li>Our Mission: </li></ul><ul><ul><li>Improve the global competitiveness of Texas’ Manufacturers by applying the appropriate techniques and technologies. </li></ul></ul><ul><li>TMAC is part of the MEP System </li></ul>TMAC works closely with Manufacturing Supply Chain to make them more competitive by providing assistance in appropriate use of technologies and techniques What is TMAC?
  3. 3. TMAC Services <ul><li>Management Controls, Systems, and Compliance </li></ul><ul><ul><li>Planning & Policy Deployment </li></ul></ul><ul><ul><li>Financial Controls and Measurement Systems </li></ul></ul><ul><ul><li>EPA, OSHA </li></ul></ul><ul><ul><li>QMS, EMS, SMS </li></ul></ul><ul><li>Culture and Workforce Development </li></ul><ul><ul><li>Supervisor and Technical Training </li></ul></ul><ul><ul><li>Teams/Team Facilitation </li></ul></ul><ul><li>Waste and Variation Reduction </li></ul><ul><ul><li>Lean and Six Sigma </li></ul></ul><ul><ul><li>TPM </li></ul></ul><ul><ul><li>EHS </li></ul></ul><ul><ul><li>Facility Design and Relocation </li></ul></ul><ul><li>Technology Application </li></ul><ul><ul><li>ERP, MRP </li></ul></ul><ul><ul><li>Automation & Mechanization </li></ul></ul>
  4. 4. Cycle Time “ One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost.” Henry Ford, 1926
  5. 5. Mass Production Value-Added Time : Minutes Time in Plant : Weeks Receiving Warehouse Kitting Springs Diodes Storage Repair Testing Shipping Warehouse Ship Material ORDER CASH LEDs
  6. 6. Defining Lean “ A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.” The MEP Lean Network Lean has been defined in many different ways.
  7. 7. Definition of Value Added Value Added Any activity that increases the market form or function of the product or service. (These are things the customer is willing to pay for.) Non-Value Added Any activity that does not add market form or function or is not necessary. (These activities should be eliminated, simplified, reduced, or integrated.)
  8. 8. Lean = Eliminating the Wastes Value Added Typically 95% of all lead time is non-value added <ul><li>Defects </li></ul><ul><li>Overproduction </li></ul><ul><li>Waiting / Busy Work </li></ul><ul><li>Non Value Added Processing </li></ul><ul><li>Transportation / Conveyance </li></ul><ul><li>Inventory </li></ul><ul><li>Motion </li></ul><ul><li>Employees Underutilized </li></ul>Non-Value Added
  9. 9. Benefits of Lean Lead Time Reduction 0 25 50 75 100 Percentage of Benefits Achieved Productivity Increase WIP Reduction Quality Improvement Space Utilization
  10. 10. Lean Strategic Initiative Elements <ul><li>Burning Platform – Operational Excellence as Key Strategy </li></ul><ul><li>Defined Roles and Responsibilities </li></ul><ul><ul><li>Management Sponsored and Driven </li></ul></ul><ul><ul><li>Mid-Management Fueled </li></ul></ul><ul><ul><li>Grass Roots Implemented </li></ul></ul><ul><ul><ul><li>Wide Spread Orientation </li></ul></ul></ul><ul><li>Formal Launch </li></ul><ul><ul><li>Need for Change </li></ul></ul><ul><ul><li>WIFM </li></ul></ul><ul><ul><li>Management Expectations </li></ul></ul><ul><ul><li>Layoff Policies </li></ul></ul><ul><li>Requires Management System </li></ul><ul><ul><li>Regular Progress Checks </li></ul></ul><ul><ul><li>Communication </li></ul></ul><ul><ul><li>Integrated Measurements </li></ul></ul><ul><ul><li>Recognition and Rewards </li></ul></ul><ul><ul><li>Project Management </li></ul></ul><ul><li>Team Culture </li></ul><ul><li>Proposal System </li></ul>Strategic Planning Lean 6 sigma Resource Accounting Work Force Develp
  11. 11. For More Information... Mark Sessumes (817)312-5853 email : [email_address] Bill Stockstill (817)917-2564 email : [email_address]

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