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Basics of Lean for Manufacturing On-Demand, Defect-Free, One-By-One at the Lowest Cost
Perception of Lean What do you see? YouTube - Terry Tate Office Linebacker
Why Are We Really Here?? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],YouTube - Best Commercial Ever Please click link for video
Who is effected by our costs? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Training Objectives ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What is Lean? ,[object Object],[object Object]
Reasons For Lean
4 Core tools of Lean ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],1 6 S P
Standard Work ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
One Piece Flow ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
10 Benefits of One Piece Flow ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Pull Systems
Pull Systems - Example
Pull Systems
Lego Exercise
What is 6S ? ,[object Object],[object Object]
6-S Objectives ,[object Object],[object Object],[object Object],[object Object]
Benefits of 6S ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Elements of 6S ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
When to do 6S ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
The 8 Wastes ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Sea of Waste
[object Object],[object Object],[object Object],[object Object],[object Object],Value Adding
Non-Value Adding ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
R.I. Events – A 7-Week Cycle ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Rapid Improvement Events ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Value and Non Value Exercise ,[object Object],[object Object],[object Object],[object Object],[object Object]
Toast
Test ,[object Object],[object Object],[object Object],[object Object]

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Basics Of Lean

Editor's Notes

  1. VSA was conducted on your area by your peersThis event was part of the action plan Lean is….
  2. If we applied the materials logic we use on the factory floor to our homes, our homes would look like this. What is wrong with this house? Would you build an addition on your house just to store toilet paper if you could get a bargain from a supplier if it was bought in large volume? Of course not! As consumers, we demand goods in a reasonable quantity and at an affordable price. Do the rooms in this house appear normal to you? Would you organize your house in this manner? Notice everything is out of place. At home, we organize things for our convenience so we can be more efficient, save time and energy. Why don?t we do this aOur material dilemma forces us to store parts where they don?t belong because of the high inventories. Thus, making parts hard to find, hard to count, and moving them long distances. Workplace organization and visual controls provide the tools we need to solve these problems.
  3. Benefit 1: Improves safety. Research shows that overexertion is one of the main sources of injury in the workplace. When we transition to one piece flow we limit the need to lift heavy pallets and containers of material.Also, one piece flow often reduces the number of forklifts moving about. Did you know there are around 90 deaths and 90,000 forklift related accidents each year in the USA alone?Benefit 2: Builds in Quality. When we “make one, move one” defects are detected immediately (usually the next work station) forcing immediate corrective action.In contrast, when batches of material are produced piles of scrap may result when a defect is detected downstream. Why?
  4. Rapid Improvement Event is AN INTENSE, FOCUSED ACTIVITY (3-4 DAYS)A TEAM FOCUSED ON A SPECIFIC AREAEach team uses specific Lean toolsROOTS: FORD PRODUCTION SYSTEMAPPLIED WHEREVER WORK IS DONEyou must learn by doingLEARN THE TOOLS BY USING THEMSET MEASUREABLE TARGETS AND GET THERE!