Lean Manufacturing has been practiced by organisations for decades. From mere tools and techniques, it has evolved as a philosophy, as a culture to be sustained at any cost. More recently, it is seen as the simplest tool which can be applied across the organisation value chain for competitiveness. It is important to understand the Lean basics first and then move on to training and execution journey. ADDVALUE Consulting Inc (AVCI) is the leader in Operations excellence, Team Excellence, Business Excellence, Life Coaching and Business Coaching across the globe. Nilesh Arora, Founder-Partner, Director of AVCI, with an experience of more than a decade in consulting for manufacturing and service sectors across a vast industrial spectrum, explains the Lean Basics, Pillars and Tools in the most simplified way for organization learning, development and effectiveness. This Presentation explains: • How to Create World Class Profitable Organizations? • What is Lean Manufacturing Management? • What is Lean Six Sigma? • What are the benefits of Lean? • Continual Learning and Development in Organizations • How to implement Operations excellence, Team Excellence, Business Excellence? • What are benefits of Lean Strategic Management? Lean Manufacturing Training Courses: http://goo.gl/XHKHjy Six Sigma Basics and Training: http://goo.gl/LikNmJ Micro and Small units: http://goo.gl/2RIjyM Test your Lean IQ: http://goo.gl/cJKs9U World’s First Couple Coach: http://goo.gl/op6jY2 Nilesh Arora You tube: http://goo.gl/gGMruK Nilesh Arora LinkedIn: http://goo.gl/LI61Hu Nilesh Arora Twitter: http://goo.gl/2J6urw Nilesh Arora Pinterest: http://goo.gl/0BfNcv Nilesh Arora G+: http://goo.gl/k8KVsq Nilesh Arora Slide Share: http://goo.gl/SjMNY4 For complete value addition through Lean Manufacturing by Lean Consultants: http://www.avci-lean.com

1. Life Coaching Business Coaching Dream Coaching
Adding Value In Totality !!
Career Enhancement with Lean
LEAN BASICS, LEAN MODEL, TFM, TPM, TQM, TSM, THM, JIT, LEAN Six Sigma – SIMPLIFIED !!
Lean Coach : Nilesh Arora
Lean Basics
www.avci-lean.com
Email : info@avci-lean.com
Operations Excellence
Team Excellence
Business Excellence
Asia Africa Australia

2. Creating World Class Organizations …
In 9 Simple Steps
By
ADDVALUE Consulting Inc.

3. What is Muda ??
Muda = WASTE in any activity
Removal of Waste = Low Through Put Time (TPT)
Increase in Value Addition Ratio
By
Identification, Reduction, Elimination of Waste
on a Continual basis helps
Organizations become
WORLD CLASS, LEAN, FIT, COMPETITIVE
&
SUSTAINABLE

4. What is Lean ?
“To achieve EXCELLENCE or even PERFECTION
by continual
IDENTIFICATION, REDUCTION & if possible ELIMINATION
of Muda (Waste - NVA)
across the value chain”

5. TOTAL LEAN MANAGEMENT ATTACK MUDAs
Identify Reduce Eliminate MUDAs
thru
VALUE ADDING WORKSHOPs
VAWs
World Class, Lean, Fit, Competitive
&
Sustainable Organizations
Unawareness of
Lean Management Tools
Muda of Transportation
Muda of Motion
Muda of Waiting
Muda of Rejection
Muda of Over Processing
Muda of Inventory
Muda of Over Production
Muda of Unused Human Potential

6. Creating World Class Organizations
Creating Lean Foundations through TOP Management Commitment & 5S
Creating World Class Organizations = “TOTAL LEAN MANAGEMENT”
TFM
TPM
TQM
TSM
THM
SUPPL
I
ERS
CUSTOMERS
TOTAL
FLOW MANAGEMENT
TOTAL
PRODUCTIVE
MAINTENANCE
TOTAL
QUALITY
MANAGEMENT
TOTAL
SERVICE
MANAGEMENT
TOTAL
HUMAN
MANAGEMENT
Identify, Reduce & Eliminate Muda (Waste) Continually - across the Value Chain
Focus
on
Quality, Cost
& Delivery
Focus
on
Quality, Cost
& Delivery
ADDVALUE
Through
TOTAL Employee Involvement (TEI)
Continual Process Improvements
Zero Defects
Application of Lean Tools
( AVCI- 9 steps)

7. Lean Pillars and Tools
Lean Pillars
Lean Tools
TFM
5S, Spaghetti Diagram, Value Stream Mapping (VSM), Cellular Manufacturing, Lean Business Process, Lean Office
TPM
Autonomous Maintenance, Planned Maintenance, Quick Changeover (SMED)
TQM
7 QC Tools, Problem Solving, Poka Yoke, Lean Six Sigma
TSM
Kanban, JIT, Spares Management, Lean Distribution, Lean Logistics, Lean Supply Chain
THM
Lean Org Structure, Lean Metrics, Lean KPIs, Lean Appraisals, Lean Counseling

8. TFM (Total Flow Management)
Production Flow
Internal Logistics Flow
External Logistics
5.Low Cost Automation
4. SMED
3. Standard Work
2. Cellular Layout
1. Line and Layout Design
5. Production Pull Planning
4. Leveling
3. Synchronization
2. Mizusumashi
1. Supermarkets
5.Pull Planning
4. Deliver Flows
3. Source Flows
2. Milk Run
1. Storage & W/house Design

10. TPM (Total Productive Maintenance)
TOTAL PRODUCTIVE MAINTENANCE
LEAN KOBETSU
AUTONOMOUS
PLANNED MAINTENANCE
EDU & TRAINNING
EQUIP. MANAGEMET
QUALITY MAINT.
LEAN OFFICE
SAFETY & ENV.
5S – (Seiri, Seiton, Seiso, Seiketsu, Shitsuke)

11. TPM Basics

12. TQM (Total Quality Management)
LEVEL 0
LEVEL 1
LEVEL 2
LEVEL 3
LEVEL 4
GOAL
Not Defined “servicing”
Reduction of Customer Complains
Reduction of Internal Complains
Reduction of Interfaces Complains
Zero Defects Value Stream Chain
SITUATION
Defect products leave the company
Defect Reduction through Inspection
Defect reduction by defect prioritization
Defect reduction by interface optimization
Defect prevention with optimized process
KEYS
Defect rate >15% high non conf. cost
Defect rate < 15% red. External defects
Defect <5% (50,000 ppm) red. External defect cost
Defect rate <10.000 ppm invest in appraisal
Defect rate <100 ppm Invest in Protection
FOCUS
Manual Workplace
Operations
Int. Sub-processes
Internal process
Whole entity
TOOLS
QC tools little known, Non systematic use of QC tools
Statistical process Control, Poka yoke
Structure problem solving with Kaizen
Structured Problem Solving with Six Sigma
Benchmarking, Design for Lean Six Sigma
PEOPLE
No or less people Involvement
Centrally organized Quality administration
Beginning involvement employees participate and are responsible
50% involvement HR-Instruments Ind. Development
100% people involvement, 100% responsibility, 100% development

13. TSM (Total Service Management)
BEST IN CLASS
Create Waste free procedures , Become a Show Case
Achievement of QCDMS targets
L6
Control Process to become
FLEXIBLE WORKING IN TEAMS
Analyze Task, Apply Mobility concept, Create flexible workstations & Layouts
Greater flexibility less space
L5
Empower People For
Optimization as a Team
Implement Visual Management, Create Team boards
VM, Policy Deployment
L4
Lock in Gains By
Process Improvement
Map document and Information Flow, Do PDCA, Leverage IT
Reduced Lead Time, Paper less Office
L3
Save Through
Co-Operation
Standardize – Procedures & forms, Officer materials, Communication
No errors or omissions
L2
Improve Through
Self Organization
Eliminate Muda, Do 5S, Set Goals, Develop Roadmap
Awareness of Waste
L1
Create a good foundation Through

14. THM (Total Human Management)
Lean KPI
Self Assessment System
Safety & Morale
Lean
Counseling
Merit Rating
System
Human Resource Development System

15. Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Creating World Class Organizations in 9 Simple Steps…
Lack of awareness of Lean Management tools
Muda of Transportation
Muda of Motion
Muda of Waiting
Hands-on
Training
TFM
5S + Muda, Mura, Muri Elimination
Muda Of
Unused
Human
Talent
Muda of Over Production
Muda of Inventory
Muda of Defects / Rework
Muda of Over Processing
Kanban, TSM
One piece / Small Batch Flow, JIT, Pull Manufacturing
Total Human Management (THM)
Lean Six Sigma, Process Standardization
TFM,TPM,TQM, Lean Office
TPM, TQM, Lean Office
Identify
Reduce
Eliminate
MUDAs’
ADDVALUE
at each step
Using
LEAN TOOLS
Step 1
WORLD CLASS
Organization

16. Lean Summarized

17. Lean Benefits
•Aligned vision
•30-40% release of space
•Through Put Time reduction
•Inventory reduction by 40 %
•50% reduction in errors, eventually Zero Defect Manufacturing thru Six Sigma
•Improved cash flow
•15-20% increase in profitability
•Improved team work

18. Test Your Lean IQ - ADDVALUE Lean Quiz