SlideShare a Scribd company logo
History of Manufacturing   ,[object Object],[object Object],[object Object],[object Object],[object Object],Pascal Dennis, pp. 1-11
What is Value?   ,[object Object],[object Object],[object Object],[object Object]
Design and Improve Value   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Value System ,[object Object],Operations 468: Manufacturing and Supply Chain Strategy Operations 460: Designing Operations
Value System for Bread ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Firm Value Chain Value Streams
Value Stream ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Value and Perfect Process ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Definitions of Lean ,[object Object],[object Object],[object Object],[object Object]
Lean Thinking ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
House of Lean
Toyota-House of Lean Pascal Dennis, pp. 20
A3 Thinking for Hard Times
Lean Enterprise Principles ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Lean Culture ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Team Presentations ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Designing and Improving Operations
Characteristics of Effective Teams ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Project Team Meetings ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Six Steps to Lean
Eight Major Wastes ,[object Object],Acronym:  D O W N T I M E Overproduction efects ,[object Object],verproduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],aiting time on-utilized people ransportation nventory otion xtra processing
Categories of Activities ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Definition of Waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Categories of Waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Distribution of Activities
House of Lean-Eight Wastes
Video: “Mercury Marine” ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Overproduction Waste Overproduction
Overproduction True Efficiency – 8 operators  100 pieces Apparent Efficiency – 10 operators  120 pieces Current State – 10 operators  100 pieces Customer “ But I only need 100 pieces”
Inventory Waste
Apex Cell Layout ,[object Object],[object Object],[object Object],Before applying guidelines After applying guidelines
Waste in U.S. Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Commentary on Waste ,[object Object],[object Object],[object Object]
Muri, Mura, Muda ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Muri = overburdened Mura = unevenness, fluctuation, variation Muda = waste No Muri, Mura, or Muda
House of Lean-Kaizen
Kaizen Principles ,[object Object],[object Object],[object Object],Kai Change  zen Good ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],                                    
DVD: “Toast Kaizen” ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
DVD: “Toast Kaizen” ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What is Work ? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise 1: Apex Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],14 Work Elements = 50 Seconds
Exercise 1: Apex Work Classification
Exercise 1: Apex Flow Diagram
Standard Work   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Standard Work Benefits   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Standard Work Definitions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Standard Work Definitions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Perspectives on Standard Work   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Standard Work Diagrams ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Operator Balance Chart and Design ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Time Work Elements ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Time Observation-Current State Map
Exercise: Time Observation Studies ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise: Time Observation Studies ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise: Standard Work Sheet  1
Exercise: First Simulation Run ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Time Observation Form ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Time Observation Form Example Problems and Exercises
Time Observation Form Example
First Simulation Run ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise: Standard Work Sheet 2
Exercise: Second Simulation Run ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Second Simulation Run ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Time Observation Form Example
Standard Work Combination Sheet ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Standard Combination Sheet Example
Operator Balance Chart ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Operator Balance Chart
Exercise: Standard Work Sheet  3
Exercise 2: Apex Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise 1: Apex Flow Diagram
Exercise 1: Apex Work Classification
Guidelines for Number of Operators
Process Study and Kaizen   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Paper Kaizen –  Operator Activity Chart ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise 3: Apex Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Exercise 1: Apex Work Classification
Assembly Line Balancing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Line Balancing Procedure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Assembly Line Balancing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Assembly Line Example
Assembly Line Diagram
Assembly Line Balancing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Assignment Heuristics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Assembly Line Balancing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Assembly Line Work Stations 1 4 3 5 2
Assembly Line - LOT
Ranked Positional Weights
Assembly Solution - RPW
Assembly Line Exercise 1 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Blackboard OPS 460 > Assignments > Assembly Line      Balancing
Assembly Exercise 1 Network
Assembly Line Exercise 2 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Blackboard OPS 460 > Assignments > Assembly Line    Balancing
Improve Cycle Time ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Superior Facility Layouts ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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