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FREE DOWNLOAD - INTRODUCTION TO LEAN PRESENTATION

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A simple introductory presentation on Lean Manufacturing. Learn about key principles of Lean Methodology and share this with your team using this simple Lean Thinking presentation.
Presentation contains a number of simple exercise that you can use to practice the Lean Methodology in your business.

Published in: Business, Technology

FREE DOWNLOAD - INTRODUCTION TO LEAN PRESENTATION

  1. 1. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL1 LEAN ENTERPRISE INTRODUCTION TO LEAN METHODOLOGY
  2. 2. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL2 WHAT IS LEAN? •  A set of principles and techniques that eliminate waste , and deliver to our customers… Ä   exactly  what they need Ä   when  they need it Ä   in the quan.ty  they need Ä   in the right sequence   Ä   without  defects   Ä   and  at the lowest  possible  cost   Value   Waste   Agility   Lead  Time  
  3. 3. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL3 LEAN IS THE TOYOTA PRODUCTION SYSTEM DEVELOPED BY TOYOTA OVER THE PAST 60 YEARS AND ADOPTED BY BUSINESSES AROUND THE WORLD
  4. 4. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL4 WHAT IS VALUE? •  Those activities that a client is willing to pay for when they engage our services. WHAT IS WASTE? •  Everything else!  
  5. 5. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL5 EXERCISE •  Define value for your product. •  What does the customer pay for when they buy your product? •  Which are the steps in your process that create that value? •  How long do those steps take? •  Compare this value adding time to the total time It takes you to process a product or customer order from start to finish. •  What do you find?
  6. 6. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL6 TYPICALLY THERE ARE SEVEN TYPES OF WASTE WE LOOK FOR IN A WORK PLACE DO YOU KNOW THEM?
  7. 7. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL7 TRANSPORT •  Moving materials and product around the site and from site to site. •  Double handling. •  Excessive mail attachments •  Travelling to and from client meetings •  Couriers T I M W O O D
  8. 8. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL8 INVENTORY •  Any form of batch processing •  Expediting and “work chasing” on a regular basis •  High levels of stationery •  Large amounts of work in progress T I M W O O D
  9. 9. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL9 MOTION •  Excessive movement of people •  Searching for information and files •  Finding data on shared or personal drives •  Swapping information between IT systems – cut and paste of data •  Moving between office equipment T I M W O O D
  10. 10. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL10 WAITING •  Waiting for a machine to finish its cycle. •  Waiting for someone else to do their job. •  Waiting form information from clients or internal departments •  Waiting for work to be checked •  Waiting for decisions to be made or approvals •  Systems response time or downtime T I M W O O D
  11. 11. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL11 OVERPRODUCTION •  Producing more than is needed sooner than it is needed •  Completing activities before they are required •  Individual targets v teamwork •  Purchasing stationery before it’s needed T I M W O O D
  12. 12. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL12 OVER PROCESSING •  Processes that don’t add value to the customer. •  Excessive sign offs. •  Duplication of paperwork or files •  Unread reports with excessive data •  Too many checklists of quality checks •  Re-entering data across systems T I M W O O D
  13. 13. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL13 DEFECTS ERRORS, MISTAKES & CORRECTIONS •  Defective product or service •  Missing or incorrect information in data •  Calculation errors in billing and invoices •  File filing errors •  Client data held in different IT systems T I M W O O D
  14. 14. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL14 EXERCISE – DO A WASTE WALK 1.  List the Seven Wastes on a sheet of paper 2.  Find a place where you can observe activity in your workplace safely.. 3.  Watch and notice the activities in your workplace, 4.  Write down all the wastes you see against the types of waste listed. 5.  Think about simple changes you could make to eliminate those wastes. 6.  Make three changes and see how they go!
  15. 15. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL15 FOUR RULES OF THE TOYOTA PRODUCTION SYSTEM Reference: Decoding the DNA of the Toyota Production System by Steven Spear and H. Kent Bowen, Harvard Business Review, Sept-Oct 1999
  16. 16. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL16 RULE 1: ALL WORK IS HIGHLY SPECIFIED IN ITS CONTENT, SEQUENCE, TIMING AND OUTCOME.
  17. 17. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL17 EXERCISE – STANDARD WORK •  Choose a task in your business. •  Get the people together who routinely do that task. •  Ask them to list the steps involved in the order that they do them. •  Get the team members to time each other doing the task to see how long it takes – try to record three or four cycles for each person. •  Check the quality and accuracy of the output and make sure that it is meeting specifications. •  If you see improvements that can be made, try them out and do the task again. •  Compare results and agree which method gives a quality outcome at the best time which all team members can work to. •  Write the new method down. •  “Bingo” you have created standard work for that task.
  18. 18. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL18 RULE 2 – EACH PERSON KNOWS WHO PROVIDES WHAT TO HIM, AND WHEN.
  19. 19. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL19 EXERCISE – UNDERSTANDING INTERNAL CUSTOMERS AND SUPPLIERS •  Introduce yourself to a front-line employee in your business. •  Ask them about their job and what they do. •  Ask them who provides them with the material and information they need (their supplier). •  Ask them who they provide materials and information to (their customer) •  Ask them how do they know what to do next after they have completed their current task? •  Ask them how they think they are performing for their customer? •  How is their supplier performing for them? •  Go and see their supplier and customer and ask them their perspective on the product and information they are receiving or supplying. •  What did you learn? •  What improvements can be made?
  20. 20. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL20 RULE 3 – EVERY PRODUCT AND SERVICE FLOWS ALONG A SIMPLE, SPECIFIED PATH.
  21. 21. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL21 EXERCISE – UNDERSTANDING A VALUE STREAM •  Choose a key product or service. •  Start at the end customer. •  What are the requirements of the customer in terms of output, quality, delivery? •  Follow the process backwards step by step through your business. •  What waste do you see? •  How can the process be simplified to eliminate waste.
  22. 22. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL22 RULE 4: Any improvement must be made in accordance with a scientific method, Under the guidance of a teacher, at the lowest possible level in the organization. PDCA Do Act Plan Check
  23. 23. © TXM Lean Solutions Pty Ltd 2012 CONFIDENTIAL23 EXERCISE – FIVE WHYS •  Think of a problem your business had in the past day – it could be a quality problem, a delivery problem or a machine breakdown – any problem. •  Get together the people who know about the problem. •  Agree a definition for the problem and write it down. •  GO to the workplace were the problem is evident •  Ask why the problem occurred. •  Continue to ask “why” five times until you get to the root cause. •  Have you found the root cause? •  Agree a corrective action, agree who is responsible for completing it and set a time for it to be completed. •  Once the corrective action is in place “check” – has the problem happened again – repeat the check for a few days or weeks until you are sure the problem has gone. •  Document the solution in your updated standard work, bills of materials, quality records or other documents.
  24. 24. Learn More: txm.com.au Contact us: info@txm.com.au

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