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Lean Manufacturing Training Course Basics - Nilesh Arora
The document outlines a comprehensive approach to creating world-class organizations through lean management principles, emphasizing the identification and elimination of waste (muda) across various processes. It details various lean tools and methodologies, including Total Flow Management (TFM), Total Productive Maintenance (TPM), and Total Quality Management (TQM), aimed at enhancing operational efficiency and employee involvement. The goal is to foster a culture of continuous improvement, resulting in reduced costs, improved quality, and increased profitability.
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Lean Manufacturing Training Course Basics - Nilesh Arora
- 1. Life Coaching BusinessCoaching 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 ClassOrganizations … 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 MANAGEMENTATTACK 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 ClassOrganizations 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 andTools 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 FlowManagement) 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 ProductiveMaintenance) TOTAL PRODUCTIVE MAINTENANCE LEAN KOBETSU AUTONOMOUS PLANNED MAINTENANCE EDU & TRAINNING EQUIP. MANAGEMET QUALITY MAINT. LEAN OFFICE SAFETY & ENV. 5S – (Seiri, Seiton, Seiso, Seiketsu, Shitsuke)
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- 12. TQM (Total QualityManagement) 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 ServiceManagement) 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 HumanManagement) Lean KPI Self Assessment System Safety & Morale Lean Counseling Merit Rating System Human Resource Development System
- 15. Step 2 Step3 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
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- 17. Lean Benefits •Alignedvision •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 LeanIQ - ADDVALUE Lean Quiz