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Lean Manufacturing 101
Lean aims to improve efficiency by identifying and eliminating waste, or non-value added activities. It focuses on delivering what customers want, when they want it, in the desired quantity, while minimizing the use of resources. There are seven types of manufacturing waste - transportation, inventory, motion, waiting, overprocessing, overproduction, and defects. Eliminating these wastes reduces lead times and improves process flow. Lean analysis identifies value-added versus non-value added steps to remove unnecessary activities from the process.
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Lean Manufacturing 101
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- 2. LEAN 101 Lean worksto improve the efficiency of any process by identifying and eliminating waste, also known as non- value added activity.
- 3. LEAN 101 An OptimizedValue Stream LEAN is a system which produces: What the customer wants…“The Right Part” When the customer wants it… “The Right Time” In the quantity the customer wants…“The Right Amount” While using the minimum: Raw Materials Equipment Labor Space
- 4. Value Adding Activities... ...transformraw materials and information into products or services which the customer wants! Non-Value Adding Activities... ...consume resources, but don't directly contribute to the product. VALUE ADD vs. NON-VALUE ADD
- 5. Value Adding Activities... ...transformraw materials and information into products or services which the customer wants! Non-Value Adding Activities... ...consume resources, but don't directly contribute to the product. VALUE ADD vs. NON-VALUE ADD
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- 7. Waste of Transportation: “Transportingparts and materials around the plant.” Causes of Transportation: ▪ Poor plant layout ▪ Poor understanding of process flow ▪ Large batch sizes ▪ Long lead times ▪ Large storage areas ▪ Double and triple handling WASTE 1
- 8. Waste of Inventory: “Inventorywaste is stock or work in process in excess of the requirements necessary to produce goods or services just in time.” Causes of Inventory ▪ Unleveled Scheduling ▪ Poor Market Forecast ▪ Unbalanced Workload ▪ Unreliable shipments by suppliers ▪ Misunderstood communications WASTE 2
- 9. Waste of Motion: “Anymovement of people or machines that does not add value.” Causes of Wasted Motion: ▪ Inconsistent work methods ▪ Unfavorable facility or cell layout ▪ Poor workplace organization ▪ Misplaced tools and equipment WASTE 3
- 10. Waste of Waiting: “IdleTime created when waiting for…” Causes of Waiting: ▪ Unbalanced work load ▪ Unplanned Maintenance ▪ Long set ups ▪ Misuses of automation ▪ Upstream quality problems ▪ Unleveled scheduling ▪ Waiting for approvals ▪ Poor communication WASTE 4
- 11. Waste of Overprocessing: “Effortadds no value to the product or service from the customers viewpoint.” Causes of Overprocessing: ▪ Product changes without process changes ▪ Just in case mentality ▪ Customer requirements undefined ▪ Large downtime ▪ Lack of Communication ▪ Redundant approvals ▪ Extra copies/excessive information WASTE 5
- 12. Waste of Overproduction: “Makingmore, earlier, or faster than is required by the next process.” Causes of Overproduction ▪ Misuse of automation ▪ Push Production Mentality ▪ Long process set up ▪ Un-level scheduling ▪ Unbalanced work load WASTE 6
- 13. Waste of Defects: “Usingresources to inspect and repair material in inventory wastes time.” Causes of Defects: ▪ Weak Process control ▪ Poor quality materials ▪ Unbalanced inventory level ▪ Deficient planned maintenance ▪ Inadequate training/work orders ▪ Product design ▪ Customer needs not understood WASTE 7
- 14. • Layout (distance) •Long setup times • Incapable processes • Poor operating practices • Poor communication • Lack of training • Lack of adherence • Poor management techniques • Ineffective production planning/scheduling • Lack of workplace organization • Quality/Reliability Issues • Unreliable equipment • More… “If it doesn’t add value, it’s waste.” Henry Ford 1920 CAUSES OF WASTE
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- 18. 1 MONTH LEADTIME WASTE ELIMINATION = TIME REDUCTION
- 19. 1 MONTH LEADTIME WASTE ELIMINATION = TIME REDUCTION
- 20. 1 MONTH LEADTIME WASTE ELIMINATION = TIME REDUCTION COMMUNICATION & INFORMATION STEPS
- 21. 1 MONTH LEADTIME WASTE ELIMINATION = TIME REDUCTION COMMUNICATION & INFORMATION STEPS PROCESSING (MANUFACTURING) STEPS
- 22. PROCESS VALUE STREAM 1MONTH LEAD TIME WASTE ELIMINATION = TIME REDUCTION
- 23. PROCESS VALUE STREAM 1MONTH LEAD TIME WASTE ELIMINATION = TIME REDUCTION The Value Stream is the focus of WASTE ELIMINATION activity!
- 24. 1 MONTH LEADTIME WASTE ELIMINATION = TIME REDUCTION
- 25. VALUE ADDIdentify whatis ---------> WASTE ELIMINATION = TIME REDUCTION 1 MONTH LEAD TIME
- 26. VALUE ADDIdentify whatis ---------> NON-VALUE ADDIdentify what is ---------> WASTE ELIMINATION = TIME REDUCTION 1 MONTH LEAD TIME
- 27. ELIMINATE NON-VALUE ADDEDSTEPS IN THE PROCESS 1 MONTH LEAD TIME VALUE ADD WASTE ELIMINATION = TIME REDUCTION
- 28. 1 MONTH LEADTIME VALUE ADD WASTE ELIMINATION = TIME REDUCTION
- 29. 7 DAY LEADTIME 1 MONTH LEAD TIME WASTE ELIMINATION = TIME REDUCTION
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