The lean team assessed the status of lean strategy implementation in an assembly unit of a company that specializes in low and medium voltage switchgear products. They formed a lean implementation team and defined key performance indicators like processing time. The existing assembly process was mapped and current performance was measured using Continuous Performance Measurement. Major wastes identified included long walk times, improper layout, and lack of tools at workstations. The lean tools implemented included redesigning the layout to reduce walking, separating tasks among operators to balance work, and providing necessary tools and parts at each station. After implementation, non-value added time decreased by 10 minutes, efficiency increased by 18%, and effectiveness increased by 22%, showing the methodology effectively improved operational performance.
In this 1-hour webinar you’ll learn what Lean is, why Lean is good for business and how some of the basic Lean concepts like 8 Wastes and Visual Management can improve and transform your operation.
Download the slides and more at https://goleansixsigma.com/webinar-introduction-to-lean/
Start your free Yellow Belt Training at http://www.goleansixsigma.com/free-lean-six-sigma-training/
Get The 8 Wastes Poster at https://goleansixsigma.com/product/the-8-wastes-poster/
In this 1-hour webinar you’ll learn what Lean is, why Lean is good for business and how some of the basic Lean concepts like 8 Wastes and Visual Management can improve and transform your operation.
Download the slides and more at https://goleansixsigma.com/webinar-introduction-to-lean/
Start your free Yellow Belt Training at http://www.goleansixsigma.com/free-lean-six-sigma-training/
Get The 8 Wastes Poster at https://goleansixsigma.com/product/the-8-wastes-poster/
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Lean Standard or Standardized Work Training ModuleFrank-G. Adler
The Lean Standard Work Training Module v3.0 includes:
1. MS PowerPoint Presentation including 66 slides covering the History of Lean Manufacturing, Five Lean Principles, The Seven Lean Wastes, Introduction to Lean Standard Work (Introduction, Objectives, Benefits), Basic Requirements of Lean Standard Work, Step-by-Step Process using the Four Lean Standard Work Worksheets & Examples, Takt & Cycle Time, Work Balancing, Quick Changeovers, and Kanban Solutions.
2. MS Excel Process Study Worksheet Template
3. MS Excel Process Capacity Worksheet Template & Example
4. MS Excel Work Chart Template & Example
5. MS Excel Work Combination Table Template & Examples
This presentation provides an exective overview of how to plan and implement lean improvements in manufacturing. It identifies and discusses the seven elements considered critical to lean implementation success.
Lean Thinking is a management philosophy based on the Toyota Production System (TPS). With Lean Thinking, you will be able to enhance value for your customers by improving service delivery and eliminating waste. Simply put, by becoming a Lean organization, you will be able to improve personal effectiveness, increase productivity and create greater customer value with less resources.
This training presentation is especially tailored for service industries. By teaching this presentation to managers and employees, they will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the principles and key concepts of Lean
2. Acquire knowledge on the key Lean methods and tools and their applications to improve personal effectiveness, value creation and waste elimination
3. Identify ways to develop “Kaizen eyes” to look for improvement opportunities
4. Describe the various Lean roles
CONTENTS
1. Introduction to Lean Thinking
2. Key Concepts of Lean Thinking
3. Overview of Lean Methods & Tools
4. Ways to develop "Kaizen Eyes"
5. Lean Roles
6. Sustaining a Lean Culture
To download this complete presentation, please visit: http://www.oeconsulting.com.sg
More Information:
https://flevy.com/browse/business-document/lean-manufacturing-160
BENEFITS OF DOCUMENT
Learn how to eliminate waste to save time and make more money.
Learn how to apply simple Lean methods and tools in the workplace to improve productivity and quality.
DOCUMENT DESCRIPTION
Lean is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the key concepts and principles of Lean
2. Acquire knowledge on the common Lean methods and tools and their applications to eliminate waste and create more value for customers
3. Identify ways to develop "Kaizen eyes" to look for improvement opportunities
4. Describe the various Lean roles
5. Define the critical success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Thinking
- The case for Lean Manufacturing
- Where did Lean originate?
- Toyota's philosophy
- Lean adoption in various environments
- Impact of Lean principles in industry
- Lean applications in manufacturing, process and service industries
- What is Lean?
- What Lean is not
- Traditional thinking versus Lean thinking
- Traditional culture vs. Lean culture
- Lean management framework
- Lean and six sigma
- Benefits of Lean manufacturing
Got a question about this presentation? Email us at support@flevy.com.
Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
This webinar covers:
• How to use value stream mapping as an organizational transformation & leadership alignment tool
• How to plan for a value stream mapping activity
• The mechanics of mapping, including key metrics
for office/service/knowledge work
• How to create an actionable Value Stream Transformation Plan
IMPROVING OSH & PRODUCTIVITY OF RMG INDUSTRIES BY IMPLEMENTING LEAN TOOLS AN...Karina Islam
The garment industry has played a pioneering role in the development of industrial sector of Bangladesh. The RMG sector is expected to grow despite the global financial crisis of 2009.As China is finding it challenging to make textile and foot wear items at cheap price, due to rising labor costs, many foreign investors, are coming to Bangladesh to take advantage of the low labor cost. Though Bangladesh produces garment with lowest cost but poor productivity. To survive and prosper in today's economic times, companies can no longer manage using financial measures alone, they have to track non-financial measures also such as customer satisfaction, brand preference, speed of response, employee satisfaction etc.Productivity can improve by applying lean tools like- 5s, JIT, Muda, Root Cause analysis, KPIs, VSM. For improving the ultimate productivity OHS of RMG sector of Bangladesh should be improved. In Ready Made Garments (RMG) sector of Bangladesh, the employees represent an organization's biggest and its most valuable asset. The company's productivity, and ultimately, its profitability depend on making sure all of its workers perform up to their full potential. This paper summarizes that how KPIs analysis improve productivity and OHS of RMG sectors. Appropriate indicators are first selected for KPI scoring then simulate the scores with the help of Adaptive Network-based Fuzzy Inference System (ANFIS) and finally illustrated how KPIs impacts on overall productivity.
“Lean” is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the common Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Manufacturing
2. Key Concepts of Lean
3. Lean Methods & Tools
4. Lean Roles
5. Sustaining a Lean Culture
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Lean Standard or Standardized Work Training ModuleFrank-G. Adler
The Lean Standard Work Training Module v3.0 includes:
1. MS PowerPoint Presentation including 66 slides covering the History of Lean Manufacturing, Five Lean Principles, The Seven Lean Wastes, Introduction to Lean Standard Work (Introduction, Objectives, Benefits), Basic Requirements of Lean Standard Work, Step-by-Step Process using the Four Lean Standard Work Worksheets & Examples, Takt & Cycle Time, Work Balancing, Quick Changeovers, and Kanban Solutions.
2. MS Excel Process Study Worksheet Template
3. MS Excel Process Capacity Worksheet Template & Example
4. MS Excel Work Chart Template & Example
5. MS Excel Work Combination Table Template & Examples
This presentation provides an exective overview of how to plan and implement lean improvements in manufacturing. It identifies and discusses the seven elements considered critical to lean implementation success.
Lean Thinking is a management philosophy based on the Toyota Production System (TPS). With Lean Thinking, you will be able to enhance value for your customers by improving service delivery and eliminating waste. Simply put, by becoming a Lean organization, you will be able to improve personal effectiveness, increase productivity and create greater customer value with less resources.
This training presentation is especially tailored for service industries. By teaching this presentation to managers and employees, they will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the principles and key concepts of Lean
2. Acquire knowledge on the key Lean methods and tools and their applications to improve personal effectiveness, value creation and waste elimination
3. Identify ways to develop “Kaizen eyes” to look for improvement opportunities
4. Describe the various Lean roles
CONTENTS
1. Introduction to Lean Thinking
2. Key Concepts of Lean Thinking
3. Overview of Lean Methods & Tools
4. Ways to develop "Kaizen Eyes"
5. Lean Roles
6. Sustaining a Lean Culture
To download this complete presentation, please visit: http://www.oeconsulting.com.sg
More Information:
https://flevy.com/browse/business-document/lean-manufacturing-160
BENEFITS OF DOCUMENT
Learn how to eliminate waste to save time and make more money.
Learn how to apply simple Lean methods and tools in the workplace to improve productivity and quality.
DOCUMENT DESCRIPTION
Lean is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.
By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.
LEARNING OBJECTIVES
1. Understand the key concepts and principles of Lean
2. Acquire knowledge on the common Lean methods and tools and their applications to eliminate waste and create more value for customers
3. Identify ways to develop "Kaizen eyes" to look for improvement opportunities
4. Describe the various Lean roles
5. Define the critical success factors for sustaining a Lean culture
CONTENTS
1. Introduction to Lean Thinking
- The case for Lean Manufacturing
- Where did Lean originate?
- Toyota's philosophy
- Lean adoption in various environments
- Impact of Lean principles in industry
- Lean applications in manufacturing, process and service industries
- What is Lean?
- What Lean is not
- Traditional thinking versus Lean thinking
- Traditional culture vs. Lean culture
- Lean management framework
- Lean and six sigma
- Benefits of Lean manufacturing
Got a question about this presentation? Email us at support@flevy.com.
Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
This webinar covers:
• How to use value stream mapping as an organizational transformation & leadership alignment tool
• How to plan for a value stream mapping activity
• The mechanics of mapping, including key metrics
for office/service/knowledge work
• How to create an actionable Value Stream Transformation Plan
IMPROVING OSH & PRODUCTIVITY OF RMG INDUSTRIES BY IMPLEMENTING LEAN TOOLS AN...Karina Islam
The garment industry has played a pioneering role in the development of industrial sector of Bangladesh. The RMG sector is expected to grow despite the global financial crisis of 2009.As China is finding it challenging to make textile and foot wear items at cheap price, due to rising labor costs, many foreign investors, are coming to Bangladesh to take advantage of the low labor cost. Though Bangladesh produces garment with lowest cost but poor productivity. To survive and prosper in today's economic times, companies can no longer manage using financial measures alone, they have to track non-financial measures also such as customer satisfaction, brand preference, speed of response, employee satisfaction etc.Productivity can improve by applying lean tools like- 5s, JIT, Muda, Root Cause analysis, KPIs, VSM. For improving the ultimate productivity OHS of RMG sector of Bangladesh should be improved. In Ready Made Garments (RMG) sector of Bangladesh, the employees represent an organization's biggest and its most valuable asset. The company's productivity, and ultimately, its profitability depend on making sure all of its workers perform up to their full potential. This paper summarizes that how KPIs analysis improve productivity and OHS of RMG sectors. Appropriate indicators are first selected for KPI scoring then simulate the scores with the help of Adaptive Network-based Fuzzy Inference System (ANFIS) and finally illustrated how KPIs impacts on overall productivity.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Productivity improvement through lean deployment & work study methodseSAT Journals
Abstract The objective of this paper is to present an overview on a new combined methodology for the efficient improvement in productivity with the help of various Work Study Methods associated with Lean Manufacturing Principles & Tools. Lean manufacturing tools are one of the most influential & most effective methodologies for eliminating wastes (MUDA), controlling quality, and improving overall performance of any machine, system or process in any industry with the complete assurance of large annual profit margins. This prescriptive paper proposes genuine solutions & concepts for implementing Work Study Methods and deploying associated lean manufacturing tools in any enterprise or industry, covering the technical, engineering, and manufacturing aspects as well as the business etiquette affairs. Lean Manufacturing together with Work Study Methods, being the most sophisticated & vast area of studies has a huge scope for implementation & deployment of their very own concepts. Keywords: 5S, Wastes (Muda), Time & Method Study, Setup Time Reduction (SUR), Standardized Work (SDW).
This presentation includes basic of PCOS their pathology and treatment and also Ayurveda correlation of PCOS and Ayurvedic line of treatment mentioned in classics.
MATATAG CURRICULUM: ASSESSING THE READINESS OF ELEM. PUBLIC SCHOOL TEACHERS I...NelTorrente
In this research, it concludes that while the readiness of teachers in Caloocan City to implement the MATATAG Curriculum is generally positive, targeted efforts in professional development, resource distribution, support networks, and comprehensive preparation can address the existing gaps and ensure successful curriculum implementation.
Executive Directors Chat Leveraging AI for Diversity, Equity, and InclusionTechSoup
Let’s explore the intersection of technology and equity in the final session of our DEI series. Discover how AI tools, like ChatGPT, can be used to support and enhance your nonprofit's DEI initiatives. Participants will gain insights into practical AI applications and get tips for leveraging technology to advance their DEI goals.
Delivering Micro-Credentials in Technical and Vocational Education and TrainingAG2 Design
Explore how micro-credentials are transforming Technical and Vocational Education and Training (TVET) with this comprehensive slide deck. Discover what micro-credentials are, their importance in TVET, the advantages they offer, and the insights from industry experts. Additionally, learn about the top software applications available for creating and managing micro-credentials. This presentation also includes valuable resources and a discussion on the future of these specialised certifications.
For more detailed information on delivering micro-credentials in TVET, visit this https://tvettrainer.com/delivering-micro-credentials-in-tvet/
Biological screening of herbal drugs: Introduction and Need for
Phyto-Pharmacological Screening, New Strategies for evaluating
Natural Products, In vitro evaluation techniques for Antioxidants, Antimicrobial and Anticancer drugs. In vivo evaluation techniques
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This slide is special for master students (MIBS & MIFB) in UUM. Also useful for readers who are interested in the topic of contemporary Islamic banking.
Exploiting Artificial Intelligence for Empowering Researchers and Faculty, In...Dr. Vinod Kumar Kanvaria
Exploiting Artificial Intelligence for Empowering Researchers and Faculty,
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at Integral University, Lucknow, 06.06.2024
By Dr. Vinod Kumar Kanvaria
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In Odoo, the chatter is like a chat tool that helps you work together on records. You can leave notes and track things, making it easier to talk with your team and partners. Inside chatter, all communication history, activity, and changes will be displayed.
A review of the growth of the Israel Genealogy Research Association Database Collection for the last 12 months. Our collection is now passed the 3 million mark and still growing. See which archives have contributed the most. See the different types of records we have, and which years have had records added. You can also see what we have for the future.
Thinking of getting a dog? Be aware that breeds like Pit Bulls, Rottweilers, and German Shepherds can be loyal and dangerous. Proper training and socialization are crucial to preventing aggressive behaviors. Ensure safety by understanding their needs and always supervising interactions. Stay safe, and enjoy your furry friends!
Acetabularia Information For Class 9 .docxvaibhavrinwa19
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2024.06.01 Introducing a competency framework for languag learning materials ...Sandy Millin
http://sandymillin.wordpress.com/iateflwebinar2024
Published classroom materials form the basis of syllabuses, drive teacher professional development, and have a potentially huge influence on learners, teachers and education systems. All teachers also create their own materials, whether a few sentences on a blackboard, a highly-structured fully-realised online course, or anything in between. Despite this, the knowledge and skills needed to create effective language learning materials are rarely part of teacher training, and are mostly learnt by trial and error.
Knowledge and skills frameworks, generally called competency frameworks, for ELT teachers, trainers and managers have existed for a few years now. However, until I created one for my MA dissertation, there wasn’t one drawing together what we need to know and do to be able to effectively produce language learning materials.
This webinar will introduce you to my framework, highlighting the key competencies I identified from my research. It will also show how anybody involved in language teaching (any language, not just English!), teacher training, managing schools or developing language learning materials can benefit from using the framework.
2. “Lean strategy” in manufacturing involves a
series of activities to minimize waste and
Non value added (NVA) operations from
production, customer relations, product
design, supplier networks and factory
management and improve the value added
(VA) process.
2
3. Lean approach was first introduced by Toyota
Production Systems, wherein the wastes highlighted
are
3
4. Applying lean strategies
incorrectly, increases the inefficiencies of an
organization's resources and reduced
employee confidence in lean strategies.
(Marvel and Standridge 2009).
Therefore, applying the appropriate lean
strategy for the specified industry is of
paramount importance.
4
5. Behrouzi and Wong (2011) reported that the
principal reasons behind the failure of the
lean practices are
1. the lack of an effective implementation
methodology.
2. inadequate understanding of lean
performance measurements needed to
evaluate the improvement in effectiveness
and efficiency .
5
6. The three core principles of lean strategy are
identified as:
1 Identification of value
2 Elimination of waste
3 The generation of smooth flow
(Womack et al., 1990)
6
7. 1. Identifying customer defined value
2. Optimizing the value stream
3. Converting the value flow smoothly by
controlling and eliminating wastes
4. Activating the demand pull by synchronizing
customer demand and information flow
5. Perfection of all products processes and
services
( Womack and Jones, 2003)
7
9. The proposed approach was implemented in
EXCEL Limited, Australia.
The company specializes in low and medium
voltage switchgear products.
This research mainly focused on electrical
control and communication cubicle assembly
RC-01 ES.
9
10. Define and assess the system
A lean implementation team is formed
Define the manufacturing performance indicators
Sketch the existing process status and map
Measure the current state of the process using CPM method
Implementation of lean tools based on the identified waste
Evaluation of effectiveness and efficiency of the proposed
approach
Continuous improvement techniques and culture10
11. Based on the perspective of customer driven
value, authors assessed the current status of
lean strategy in the assembly unit.
11
13. The commonly used Performance indicators
are time ,cost ,quality and flexibility.
In this study the authors focused on the
“Time” associated with the assembly
process.
Continuous Performance Measurement(CPM)
method is used in this research to assess the
current state of performance.
13
14. Sketch the existing process status and map
using VSM, visual control and time study
method.
This map represents all the existing wastes, NVA
activities in a process that transforms raw
materials into a finished good.
Major steps in the production process are:
1 receipt of raw material
2 assembly of the cubicles at different stages
3 testing
4 inspection
5 packaging
14
17. The the existing process layout for RC cubicle
assembly process was responsible for major part
of time wastes and therefore redesigned the
layout. The work station had been separated
with specific task allocations for each operator
which ultimately balanced the workloads.
Handling problems were identified as the
second most crucial waste in the process
Third was the shortage of working parts and
tools in work stations, overcomed by providing
different trolleys in each work station with
necessary tools and parts.
17
19. A major part of the proposed methodology is
to continuously assess performance before
and after lean implementation.
In this process, the first step is to measure
the current state of the process in terms of
efficiency, effectiveness, VA/NVA time ratio
using process map and CPM.
19
20. Before Lean After Lean Improvement
Value Added Time (minutes) 27.15 27.15
Non-value added time
1.Adjusting parts 2.65 2.65 0
2.Walk to hold parts 6.03 1.93 -4.1
3.Walk to get tools 2.45 0.27 -2.18
4.Get parts 5.8 3.15 -2.65
5.Unpack and disassembly 5.15 5.15 0
6.Inspection/paper works 2.5 2.5 0
7.Handling parts and tools 7.46 5.91 -1.55
8.Cleaning 1.03 1.03 0
9.Rework 1.39 1.39 0
Total (Non Value added time) 34.46 24.34 -10
Total (VA+NVA) 61.61 51.49 -10
VA/NVA ratio .79 1.12 42%
20
21. The overall performance of the
manufacturing process is measured by
considering both effectiveness and efficiency
of the production process.
Efficiency = (output value ) × 100%
(input resource )
= no of output × average pitch time × 100%
no of workers × total allocated time
21
22. Effectiveness compares actual output to
targeted output from a production line
(Bayou and de Korvin, 2008).
Effectiveness
= Actual number of output × 100%
Targeted output value
22
23. Before Lean After Lean Improvement
Daily Production Target 20 26
Achieved Production Target 12 19
Average pitch time 61 51 -10
EFFICIENCY (%) 61 72 +18
EFFECTIVENESS 60 73 +22
23
24. Monthly meeting and discussions among the
operators.
And they discussed about new innovations or
new techniques to be implemented in their
production floor to reduce NVA operations
and effective use of available resources.
5S
Kaizen
24
25. Many companies may not have expert lean
team and lean corporate culture .
Identification of key performance indicators
is also crucial for leanness evaluation.
Sometimes, it is not possible to identify and
measure all the performance indicators in a
specific company.
Finally, implementation of this method may
be costly and time consuming .
25
26. The overall achievement in reducing NVA
time , average processing time and
improvement in process efficiency and
effectiveness were found satisfactory for the
company.
The proposed lean implementation
methodology can be applied in
manufacturing organizations (especially in
assembly productions) to improve
operational performance.
26
27. Azharul Karim and Kazi Arif-Uz-Zaman, A methodology for
effective implementation of lean strategies and its
performance evaluation in manufacturing organizations, J.
Business Process Management, Vol. 19 No. 1, (2013 ), PP
169-195.
Manimay Ghosh, Lean manufacturing performance in Indian
manufacturing plants, Journal of Manufacturing Technology
Management, Vol. 24 No. 1, (2013) , PP 113-122.
27
32. The lean team found that the existing process layout for
RC cubicle assembly process was responsible for major
part of time wastes and therefore redesigned the layout.
In the new layout, the working stations and the machines
are located in optimum distance for operators which
actually reduced walking distances among them.
Handling problems were identified as the second most
crucial waste in the process. The work station had been
separated with specific task allocations for each operator
which ultimately balanced the workloads. Eventually the
handling waste was minimized by the separation of the
tasks.
In order to overcome the problem related to shortage of
parts and tools in work stations, different trolleys in each
work station was allocated with necessary tools and
working parts
32
33. Asses the status of Lean Strategy in the company
A lean implementation team is formed
The team further defines the manufacturing performance
indicators based on production quantity, processing time and cost.
Sketch the existing process status and map using VSM, visual control
and time study method to identify existing process wastes
Measure the current state of the process using CPM method
Different lean tools are implemented considering existing
production scopes and wastes into the process.
Again the effectiveness and efficiency of the proposed process
is evaluated in the next phase using CPM
The culture for continuous improvement techniques is
developed within the process environment 33
35. Before Lean After Lean Change
Value Added Time (minutes) 27.15 27.15
Non-value added time
Adjust 2.65 2.65 0
Walk to parts 6.03 1.93 -4.1
Walk to get tools 2.45 0.27 -2.18
Get parts 5.8 3.15 -2.65
Unpack and disassembly 5.15 5.15 0
Inspection/paper works 2.5 2.5 0
Handling 7.46 5.91 -1.55
Cleaning 1.03 1.03 0
Rework 1.39 1.39 0
Total (Non Value added time) 34.46 24.34 +10
Total (VA+NVA) 61.61 51.49 +10
VA/NVA ratio .79 1.12
Daily Target 20 26
Achieved Target 12 19
Average pitch time 61 51 +10
Efficiency 61 72 +11
Effectiveness 60 73 +1335
36. The method suggests that at early stage of lean
implementation, a lean team needs to be formed
with skilled personnel from different department of
the company. The team members should have
sufficient expertise in lean strategies and
implementation methodology. Many companies may
not have people with this expertise.
A team member without necessary knowledge and
skills adversely affect the overall success of the
project and can measure unrealistic performance of
production system.
Identification of key performance indicators is also
crucial for leanness evaluation. Sometimes, it is not
possible to identify and measure all the measures of
performance indicators in a specific company.
Finally, implementation of this method may be costly
and time consuming but new methods and techniques
need to be applied within company‟s budget and
resources.
36
37. Lean techniques provided better results
depending on the firm size; practices such as
setup time reduction, multifunction employees
and Kanban system provide better organizational
performance regardless of firm size.
Wan and Chen (2009) identified 12 groups of lean
tools (Autonomation, concurrent engineering,
line balancing, manufacturing cell, productivity,
pull, quality, single minute exchange of die
(SMED), standard work, visual control, VSM, and
worker flexibility) to implement in two type of
systems
(quantitative and repetitiveness of product).
37
38. VSM technique developed by Rother and
Shook (1999) becomes one of the most
commonly used lean tools.
Melton (2005) also suggested five key lean
tools especially for process industries
namely,
( kanban, 5S, visual control, Poke Yoke and
SMEDs.)
38
39. set up monthly meeting and discussions
among the operators. In these meetings,
they discussed about new innovations or new
techniques to be implemented in their
production floor.
The overall achievement in reducing NVA
time and average processing time and
increment in process efficiency and
effectiveness were satisfactory
39
41. To meet such expectations, the
manufacturing industry is focusing on
advanced manufacturing strategies in
particular the
„manufacturing-task strategy‟ and
„manufacturing-choice strategy‟
(Miller and Roth 1994, Swink and Way 1995).
41
42. The manufacturing-task strategy represents
the competitive capability the manufacturing
firm must accomplish in order to compete
successfully in its business or marketing
environment
(Davies and Kochhar2002, Leung 2002)
42
43. The manufacturing-choice strategy
represents the appropriate selections of
technologies and management strategies to
improve the manufacturing system.
43
45. The RC control and communications cubicle
is a microprocessor-based controller that
provides a directional over current, earth
fault and sensitive earth fault relay, auto
reclosing relay, instantaneous metering,
event log, demand logger and remote
terminal unit (RTU) for remote control in a
single package.
45