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Lean Principles
Anand Subramaniam
Lean Principles
2
Lean Principles
3
Deliver only what is needed,
when it’s needed
Complete elimination of non
value added activities
Avoid defects and bottlenecks (Rework, Errors, Waiting)
Eliminate steps that don’t
create value and cause waste
Most customers just want a
solution to their problem
Value
4
Deliver Value
5
What is Value?
6
Value (Non) Add
7
Where to focus?
8
NVA Time
99%
VA
1%
Order
Delivery
Focusing on non value added (NVA) has the largest
opportunity for improvement
Increase Value & Eliminate Waste
9
@ Gemba
10
Ohno Circle
11
Grasp
the
situation
3 Mu’s
12
Review Current Process
13
@ Gemba – Observation Sheet
14
Waste Types
15
Sources of Waste
16
Sources
of Waste
No standards, non-
compliance with
standards
Equipment / system failures
Lack of integrated
systems & poor system
functionality
No method to
prevent and / or
catch errors
Poor communication
Disorganized
workspace
No visibility to
performance
Ineffective design /
layout of facilities
Fragmented, poorly
designed processes
Inadequate or no training
Unbalanced
workloads
Overburden or
unreasonable demand
Lack of informationRegulatory constraints
Waste in Manufacturing
17
Waste in Services
18
Time
19
Lead Time Reduction
20
Idle Time & Process Time
21
Takt, Cycle & Lead Time
22
Takt Time Calculator
23
Target
Actual
Notes
Rounded
Up
Value Stream
24
Why create a Value Stream?
25
How many Value Stream Participants?
26
7 + 2
1/3 – SME / PO
1/3 – Cus / Sup
1/3 - Outsider
Challenge the Status Quo
27
Current VSM & Waste Identified
28
Waste Removed & Future VSM
29
ECRS Work Analysis Sheet
30
ECRS - Questions
31
Lead Time Calculation
32
18,400/20
= 920/day
4,140/920
= 4.5/day
Some Errors !!
33
No Information
flows to process
Flow
34
Flow
35
Improved Flows
36
Pull
37
Push vs. Pull
38
Perfection
39
Lean Pillars – Strive for Perfection
40
Strive for Excellence
41
Sustain the Improvement
42
43
Good Luck
http://www.linkedin.com/in/anandsubramaniam

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Lean principles