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LEARNING OUTCOME:
• Understand the concepts of Lean Thinking
• Awareness of the 7 Wastes in Industries
Lean Thinking is…
• A systematic approach
• To identifying and eliminating waste
• Through continuous improvement
• By flowing the product/ information
• At the pull of the customer
• In pursuit of perfection
LEAN means CHANGE!
• Principle of “Just Enough”
• Practice of Questioning and Experimenting
3 Types of Work in LEAN Environment
• Value Added
•Activity that changes the fit, form, or function
•Done right the first time
•Something the customer is willing to pay for
• Non-Value Added, but essential (at the moment)
– Activities that take time or resources, but do not
directly contribute to product/ service
– Incidental, or
• WASTE = MUDA
Muda = “WASTE”
Muda?
Any activity that consumes
resources without creating
value for the customer
Or
Any activity for which the
customer is not willing to
pay.
1. OVERPRODUCTION
Producing greater quantities more than the customer demand
Examples:
• Batching schedule
• Excess Printing
• Multiple forms with the same information
Learn to see overproduction!
Overproduction is the worst form of waste
Because it generates and hides others wastes such as inventory, defects and excess transport
How do we eliminate them - Let’s connect the two processes and just keep 1 piece between x and y.
Without question there is some WIP
between process x and process y. That
is the waste of overproduction
2. INVENTORY
Keeping unnecessary raw materials, parts, WIP (work-in-
process), and finished goods. More precisely, keeping more
than the minimum stock necessary for a well controlled pull
system.
Examples:
• Large batch sizes
• Wrong quantities of required items
on hand
• Paperwork in process
Accumulation
See stops, delays, or accumulation by
focusing on the flow of the product
Movement and Conveyance
See non-value creating motion by focusing on the
movement of people and machines.
Try looking from these viewpoints
Try looking from these viewpoints
Lowering the water level…
3. WAITING
Operator standing idle as machines cycle, equipment fails, parts
delay, etc.
Examples:
• Operators without work
• Low rhythm of the operators
4. MOTION
Operators making movements that are creating no value. We
can also identify waste in the motion of machines.
Examples:
• Not standardized workstation equipment
• Wrong spaced equipment
• Difficult access to the components
5. TRANSPORTATION
Transportation or conveyance itself is waste because it creates
no value. Obviously, [arts and products must be transported,
but any movement beyond the absolute minimum is muda.]
Examples:
• Loading and Unloading are
very complicated
• A large number of means of transport
6. DEFECTS
Inspection, rework and scraps.
Examples:
• A lot of rejected parts
• Difficulties during assembly
• Long repair jobs
• Irregular operations
7. OVER PROCESSING
Unnecessary or incorrect processing.
Examples:
• Differences between the standard
and the activity
• A lot of activity which does not add
any value from the point
Goal: Highest quality, lowest cost and shortest lead time
Just-In-Time Jidoka
*Takt Time
*Continuous
Flow
*Pull System
*Stop &
Notify for
Abnormalities
*Separate
human and
machine
work
The House of
TPS (Lean)
Heijunka Standardized Work Kaizen
S T A B I L I T Y
Introduction to lean thinking

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Introduction to lean thinking

  • 1.
  • 2. LEARNING OUTCOME: • Understand the concepts of Lean Thinking • Awareness of the 7 Wastes in Industries
  • 3.
  • 4. Lean Thinking is… • A systematic approach • To identifying and eliminating waste • Through continuous improvement • By flowing the product/ information • At the pull of the customer • In pursuit of perfection LEAN means CHANGE!
  • 5. • Principle of “Just Enough” • Practice of Questioning and Experimenting
  • 6. 3 Types of Work in LEAN Environment • Value Added •Activity that changes the fit, form, or function •Done right the first time •Something the customer is willing to pay for • Non-Value Added, but essential (at the moment) – Activities that take time or resources, but do not directly contribute to product/ service – Incidental, or • WASTE = MUDA
  • 7.
  • 8. Muda = “WASTE” Muda? Any activity that consumes resources without creating value for the customer Or Any activity for which the customer is not willing to pay.
  • 9. 1. OVERPRODUCTION Producing greater quantities more than the customer demand Examples: • Batching schedule • Excess Printing • Multiple forms with the same information
  • 10. Learn to see overproduction! Overproduction is the worst form of waste Because it generates and hides others wastes such as inventory, defects and excess transport How do we eliminate them - Let’s connect the two processes and just keep 1 piece between x and y. Without question there is some WIP between process x and process y. That is the waste of overproduction
  • 11. 2. INVENTORY Keeping unnecessary raw materials, parts, WIP (work-in- process), and finished goods. More precisely, keeping more than the minimum stock necessary for a well controlled pull system. Examples: • Large batch sizes • Wrong quantities of required items on hand • Paperwork in process
  • 12. Accumulation See stops, delays, or accumulation by focusing on the flow of the product Movement and Conveyance See non-value creating motion by focusing on the movement of people and machines. Try looking from these viewpoints
  • 13. Try looking from these viewpoints Lowering the water level…
  • 14. 3. WAITING Operator standing idle as machines cycle, equipment fails, parts delay, etc. Examples: • Operators without work • Low rhythm of the operators
  • 15. 4. MOTION Operators making movements that are creating no value. We can also identify waste in the motion of machines. Examples: • Not standardized workstation equipment • Wrong spaced equipment • Difficult access to the components
  • 16. 5. TRANSPORTATION Transportation or conveyance itself is waste because it creates no value. Obviously, [arts and products must be transported, but any movement beyond the absolute minimum is muda.] Examples: • Loading and Unloading are very complicated • A large number of means of transport
  • 17. 6. DEFECTS Inspection, rework and scraps. Examples: • A lot of rejected parts • Difficulties during assembly • Long repair jobs • Irregular operations
  • 18. 7. OVER PROCESSING Unnecessary or incorrect processing. Examples: • Differences between the standard and the activity • A lot of activity which does not add any value from the point
  • 19. Goal: Highest quality, lowest cost and shortest lead time Just-In-Time Jidoka *Takt Time *Continuous Flow *Pull System *Stop & Notify for Abnormalities *Separate human and machine work The House of TPS (Lean) Heijunka Standardized Work Kaizen S T A B I L I T Y

Editor's Notes

  1. Lean is all about value creation Key concept is not to make someone work faster, but rather to streamline the process to make it work faster
  2. Key points for finding wastes: Look at where products, materials or wip are accumulating Look for places where people are moving around or hand-offs of products Inventory hides problems
  3. Lowering the water level, means lowering the inventories that we have. The reason why we continuously reduce the batch size, ex. Cutting from 400 – 120 – is because if there’s too many the problems become invisible. We do not see the breakdown of machines as problems because there are available products We do not see the skill deficiency of people, because we can always tick the conveyors to make it work faster