What is Lean Process Improvement?, What is Lean?, Why Lean, Link between Lean and Profitability, Goals of Lean Process Improvement, Eliminate Waste, Waste Removal, Improve Quality, Reduce Total Costs, Reduce Processing Time, Effective Lean Implementation, The Seven Deadly Wastes, TIMWOOD, Lean Tools, Just-In-Time (JIT), Kaizen, Value Stream Mapping, Gemba (The Real Place), eighth waste,under-utilization of people

2. What is Lean Process Improvement?
Is it skinny?
Is it less people?
Is it working harder?
Is it making less?
What is Lean?

3. What is Lean
• Lean is a continuous improvement
methodology focused on managing
processes, and improving them by
compressing time, rather than sweating
assets
• Every business is a collection of processes—
primary processes that create value and
secondary processes that support them
(office and administrative functions)
• Processes are sequences of steps that must
be carried out to create value for customers
and managed as a whole, not separately
TotalCosts
Sales/Product Family
Lean reduces total costs enabling you to maintain or lower your
prices and increase market share, thereby growing your business.
• Lean emphasizes the prevention of waste: any extra time, labor or material spent producing a product or service
that doesn’t add value to it.
• Lean’s unique tools, techniques, and methods can help you reduce costs, achieve faster delivery and shorten lead
times
• Lean fosters a culture in which all employees continually improve their skill levels and processes thereby increasing
morale
• Because lean systems are customer driven, products and services are created and delivered in the right amounts, to
the right location, at the right time, and in the right condition
• Products and services are produced only for a specific customer order rather than being added to inventory

4. Why Lean

5. Goals of Lean Process Improvement
Improve Quality-
Quality is the ability of your product or services
to meet or exceed your customers’
requirements.
Reduce Processing Time-
Lead time is the total time it takes to complete a
series of tasks within a process.
Ex- The time it takes to transform raw materials
into finished goods
The time it takes to introduce new products after
the design phase is completed
Eliminate Waste-
Waste is the activities that take up time, resources
and space but does not add value to a product or
service—customers do not want to pay for non-
value-added activities.
Reduce Total Costs-
Total costs are the direct and indirect costs
associated with the production of a product or
service.
To reduce total cost a Lean process must eliminate
waste and reduce lead/processing time.

6. The Seven Deadly Wastes
The ultimate lean target is the total
elimination of waste.
Waste, or muda, is anything that
adds cost or time without adding
value.
Seven deadly waste have been
identified over the years. Recently
an eighth waste has been
identified—underutilization of
people.

7. TIMWOOD
1. Transportation- Unnecessary movement of materials such as WIP, materials being transported
from one operation to another
2. Inventory- Excess inventory that is not directly required for current customer orders
3. Motion- Extra steps taken by employees and equipment to accommodate inefficient process
layout, defects, reprocessing, overproduction. More walking, reaching or bending than
necessary
4. Waiting- The period of inactivity in a downstream process that occurs because an upstream
activity does not deliver on time
5. Overproduction- Excessive use of resources—producing too much of something, faster than
needed, or before it is needed
6. Over-processing- Extra operations, such as rework, reprocessing, such as checking someone
else’s work. Obtaining multiple signatures, or excessive reviews
7. Defects - Refers to all processing required creating a defect or mistake and the additional work
required to correct it
8. Underutilization of People - is a result of not placing people where they can (and
will) use their knowledge, skills, and abilities to the fullest
•Assigning an employee to two jobs due to understaffing
• Having employees perform a task that is politically motivated
•Not cross training employees

8. Lean Tool What Is It? How Does It Help?
5S Organize the work area:
 Sort (eliminate that which is not needed)
 Set In Order (organize remaining items)
 Shine (clean and inspect work area)
 Standardize (write standards for above)
 Sustain (regularly apply the standards)
Eliminates waste that results from a
poorly organized work area (e.g.
wasting time looking for a tool).
Just-In-Time (JIT) Pull parts through production based on customer demand instead of
pushing parts through production based on projected demand.
Highly effective in reducing inventory
levels. Improves cash flow and reduces
space requirements.
Value Stream
Mapping
A tool used to visually map the flow of production. Shows the current
and future state of processes in a way that highlights opportunities
for improvement.
Exposes waste in the current processes
and provides a roadmap for
improvement through the future state.
Gemba (The Real
Place)
A philosophy that reminds us to get out of our offices and spend time
on the production floor – the place where real action occurs.
Promotes a deep and thorough
understanding of real-world
manufacturing issues – by first-hand
observation and by talking with plant
floor employees.
Kaizen Kaizen is about organizing events focused on improving specific areas
within the company. These events involve teams of employees at all
levels, with an especially strong emphasis on involving floor
employees
Combines the collective talents of a
company to create an engine for
continually eliminating waste from
manufacturing processes.
Ref:- http://www.leanproduction.com/top-25-lean-tools.html