The goal of Lean Warehouse 101 is to equip distributers to be more competitive in their respective markets. Through understanding how to implement Lean Principles, participants can make changes in their facility that will eliminate waste, maximize productivity and increase profits. The class will yield immediate results as students return to their workplace with an understanding of waste and how to begin eliminating it from the process.
A great class for distributers, warehouses, logistics companies or any company that has warehousing operations.
Industrial Solutions - ISI crafted this course with management of all levels in mind, front-line supervisors to CEOs. These leaders may not always be running events, but they need to be able to speak the language and understand the concepts enough to fully support the Lean initiative.
This course goes deep into the cultural change a Lean transition will bring. Spread out over four 8-hour days, the course takes students through the lean tools, but with an emphasis on culture change and leadership’s role in the process. Loaded with case studies, breakout sessions, and hands-on exercises, the course has been designed to engage students and get them to practice the concepts in the classroom environment.
It's 32 hours of intense, interactive and fun training that will invigorate leaders with a new understanding of their role in a Lean company.
In this workshop, the participants will learn Lean tools and insights to remove waste in the warehouse leading to efficient, effective logistics & warehousing, reduced costs and improved service. Participants will then participate in a simulation exercise. The participants will experience the benefits of reduced costs and increased productivity.
This document provides an overview of applying lean tools and techniques to warehouse operations. It discusses seven types of waste in operations and introduces several lean tools including 5S, process mapping, standard work, slotting, cross slotting, and workload leveling. The document suggests that applying lean principles can help service customers better by reducing waste and involving warehouse employees. It also cautions that lean is a long-term cultural change and choosing the right tools is important.
This document summarizes two Lean initiatives at Loram: a receiving kaizen event and a proposed shipping kaizen event.
The receiving kaizen aimed to streamline the receiving process to reduce handling of materials and travel distances. Goals were to reduce receiving time by 50% and reduce material travel and touches by 50% and 33% respectively. The event took place from 3/10/14 to 3/21/14 and involved creating a 5S area, mapping processes, and implementing visual controls and standard work.
The proposed shipping kaizen aims to streamline shipping processes to reduce non-value added time by 50%. Goals are to designate space for work-in-process and finished goods, implement one
Lean manufacturing aims to maximize value and minimize waste in production. It focuses on eliminating waste in all areas including customer relations, product design, supplier networks, and factory management. The goal is to incorporate less effort, inventory, time, and space while producing high quality products efficiently. Key aspects of lean include specifying customer value, value stream mapping to identify waste, using a pull system triggered by customer demand, empowering employees, and continuously improving. Techniques like 5S workplace organization, standard work, visual controls, total productive maintenance, and just-in-time production help implement lean principles.
This document provides an overview of lean manufacturing principles. It defines lean manufacturing and the lean enterprise as philosophies focused on minimizing waste and meeting customer needs. The key aspects of lean covered include identifying the seven types of waste, implementing 5S techniques, designing cellular manufacturing layouts, using just-in-time processes, and value stream mapping to optimize workflow. The goals of lean are to continuously improve processes, reduce costs and lead times, and increase quality and efficiency.
The document discusses the seven types of wastes in manufacturing: motion, transportation, waiting time, overproduction, processing time, defects, and inventory. It provides characteristics and causes of each waste type. The Toyota Production System aimed to eliminate waste from manufacturing operations through identifying and removing unnecessary functions. Lean manufacturing focuses on continuously improving processes by training employees to recognize and remove all forms of waste.
Ship Right Warehousing Solutions experienced a 17% increase in customer demand overnight but lacked the resources to efficiently pick and stage orders. Lean Training Resources consultants optimized Ship Right's warehouse layout [1] by relocating faster moving products and grouping products ordered together, creating "supermarkets" for top customers. This reduced travel and picking times. As a result, Ship Right reduced monthly labor costs by $26,000 on average, improved on-time shipments by 11%, increased outbound pallets per hour by 1.67, and reduced customer complaints by 47%.
Industrial Solutions - ISI crafted this course with management of all levels in mind, front-line supervisors to CEOs. These leaders may not always be running events, but they need to be able to speak the language and understand the concepts enough to fully support the Lean initiative.
This course goes deep into the cultural change a Lean transition will bring. Spread out over four 8-hour days, the course takes students through the lean tools, but with an emphasis on culture change and leadership’s role in the process. Loaded with case studies, breakout sessions, and hands-on exercises, the course has been designed to engage students and get them to practice the concepts in the classroom environment.
It's 32 hours of intense, interactive and fun training that will invigorate leaders with a new understanding of their role in a Lean company.
In this workshop, the participants will learn Lean tools and insights to remove waste in the warehouse leading to efficient, effective logistics & warehousing, reduced costs and improved service. Participants will then participate in a simulation exercise. The participants will experience the benefits of reduced costs and increased productivity.
This document provides an overview of applying lean tools and techniques to warehouse operations. It discusses seven types of waste in operations and introduces several lean tools including 5S, process mapping, standard work, slotting, cross slotting, and workload leveling. The document suggests that applying lean principles can help service customers better by reducing waste and involving warehouse employees. It also cautions that lean is a long-term cultural change and choosing the right tools is important.
This document summarizes two Lean initiatives at Loram: a receiving kaizen event and a proposed shipping kaizen event.
The receiving kaizen aimed to streamline the receiving process to reduce handling of materials and travel distances. Goals were to reduce receiving time by 50% and reduce material travel and touches by 50% and 33% respectively. The event took place from 3/10/14 to 3/21/14 and involved creating a 5S area, mapping processes, and implementing visual controls and standard work.
The proposed shipping kaizen aims to streamline shipping processes to reduce non-value added time by 50%. Goals are to designate space for work-in-process and finished goods, implement one
Lean manufacturing aims to maximize value and minimize waste in production. It focuses on eliminating waste in all areas including customer relations, product design, supplier networks, and factory management. The goal is to incorporate less effort, inventory, time, and space while producing high quality products efficiently. Key aspects of lean include specifying customer value, value stream mapping to identify waste, using a pull system triggered by customer demand, empowering employees, and continuously improving. Techniques like 5S workplace organization, standard work, visual controls, total productive maintenance, and just-in-time production help implement lean principles.
This document provides an overview of lean manufacturing principles. It defines lean manufacturing and the lean enterprise as philosophies focused on minimizing waste and meeting customer needs. The key aspects of lean covered include identifying the seven types of waste, implementing 5S techniques, designing cellular manufacturing layouts, using just-in-time processes, and value stream mapping to optimize workflow. The goals of lean are to continuously improve processes, reduce costs and lead times, and increase quality and efficiency.
The document discusses the seven types of wastes in manufacturing: motion, transportation, waiting time, overproduction, processing time, defects, and inventory. It provides characteristics and causes of each waste type. The Toyota Production System aimed to eliminate waste from manufacturing operations through identifying and removing unnecessary functions. Lean manufacturing focuses on continuously improving processes by training employees to recognize and remove all forms of waste.
Ship Right Warehousing Solutions experienced a 17% increase in customer demand overnight but lacked the resources to efficiently pick and stage orders. Lean Training Resources consultants optimized Ship Right's warehouse layout [1] by relocating faster moving products and grouping products ordered together, creating "supermarkets" for top customers. This reduced travel and picking times. As a result, Ship Right reduced monthly labor costs by $26,000 on average, improved on-time shipments by 11%, increased outbound pallets per hour by 1.67, and reduced customer complaints by 47%.
Lean manufacturing aims to eliminate waste by focusing on value-added activities. It was developed based on the Toyota Production System and considers seven types of waste. Key Lean principles include specifying value from the customer perspective, making value flow without interruptions, and continuously improving processes through eliminating waste. Techniques like 5S, standard work, visual management, and value stream mapping are used to implement Lean.
Improve warehouse productivity - business breakfast sessionSukesh Ned
Sukesh Ned presents to Cumberland Business Chamber members how to optimise warehouse productivity via:
- industrial engineering techniques
- automated processes
- staff redeployment
and other techniques in April 2015
This document discusses lean manufacturing and its basic elements. Lean manufacturing aims to eliminate waste and reduce costs by focusing on continuous improvement, pull systems that minimize inventory, and reducing lead times. The key elements of lean manufacturing are pull systems that produce only to meet demand, reducing lead times through preventative maintenance and cell manufacturing, and continuous improvement through kaizen. The document outlines the seven types of waste lean aims to eliminate: overproduction, waiting, transportation, inappropriate processing, inventory, motion, and defects.
Lean production is a systematic method to eliminate waste from manufacturing. It identifies seven types of waste including transportation, inventory, unnecessary movement, waiting, overproduction, overprocessing, and defects. The key elements of lean production include flexible resources, cellular layouts, a pull system using kanbans, small lot sizes, quick changeovers, uniform production levels, quality at the source, and total productive maintenance. Implementing these elements can help reduce costs and inventory while improving quality, productivity, and flexibility. However, lean production requires steady demand and discipline.
The document summarizes the current issues with an electronics shop's layout and organization. Parts are scattered across multiple floors and areas, leading to lost time finding parts and unclear job flow. The goals are to decrease setup time by 50% through a more efficient layout and organized storage of parts and tools. Countermeasures proposed include centralized storage of parts in bins, clear labeling of job status, standardized wire and fastener inventory, and moving work stations to improve flow. Follow up items ensure the new processes are followed and the success of changes.
This document provides an overview of Lean fundamentals and tools. It discusses the history and evolution of manufacturing, the key principles of Lean thinking around value, value streams, flow, pull and perfection. It then describes the basic Lean tools for identifying and eliminating waste, including takt time, time observation, bar charts, spaghetti diagrams, standard work, visual management and pull systems. The goal of these tools is to optimize workflow, reduce waste and enable continuous improvement through establishing standard processes and engaging employees.
This document outlines how to implement the 5S methodology to organize and improve efficiency in a laboratory environment. The 5S system includes five phases: Sort, Set in Order, Shine, Standardize, and Sustain. Benefits of 5S include increased safety, employee involvement, organization, cleanliness, and space savings. Key aspects of implementation involve sorting necessary from unnecessary items, determining locations for necessary items, developing standard operating procedures, establishing performance measures, and sustaining practices through daily checklists and audits. Successful 5S requires commitment from all laboratory personnel.
Know about Just-In-Time and Lean manufacturing system. Find benefits and difference between JIT and Lean Manufacturing by Nilesh Arora, a founder of AddValue Consulting Inc.
- Learn a step-by-step description of an ideal approach to benchmarking.
- Why qualitative and quantitative benchmarking go hand-in-hand.
- Steps to setting up a benchmarking program
Presented by: Michael Mikitka, CEO, Warehousing Education & Research Council (WERC)
November 28, 2012 - Consumer Goods Supply Chain Officer Summit 2012 - Shanghai Pudong, China
The document provides an overview of lean office concepts including defining value from the customer's perspective, identifying value streams to reduce waste, using pull systems to optimize production to customer demand, and continuously improving processes to eliminate defects. It discusses benefits such as reduced costs, delivery times, and improved quality and customer satisfaction. Specific lean tools are outlined like 5S, visual controls, mistake proofing, quick changeovers, and using metrics like Six Sigma to measure and improve processes.
The document discusses Lean Production principles including eliminating waste, simplifying procedures, and speeding up production. It describes the seven types of waste targeted in Lean (overproduction, waiting, transportation, inventory, motion, over-processing, defective products). Benefits of Lean include reducing costs, lead times, inventory, and increasing quality and flexibility. Additional Lean tools discussed include Kaizen (continuous improvement), Poka-Yoke (mistake proofing), Kanban (pull system), and Jidoka (quality at source).
Applications of lean manufacturing toolsIshmam Ahmed
Lean Tools application with powerpoint animation. all processes are easily described with images & animation.
Uploaded by
Ishmam Ahmed
Industrial & Production Engineering (IPE)
Shahjalal university of science & Technology, Sylhet, Bangladesh
Lean manufacturing is a systematic method for waste minimization ("Muda") within a manufacturing system without sacrificing productivity.http://www.vpresentationslides.com/lean-manufacturing-ppt/
This presentation introduces lean manufacturing and identifies the eight types of waste. Lean manufacturing aims to eliminate waste through continuous improvement. The eight types of waste are overproduction, over processing, rework, waiting, excess inventory, excess motion, excess transportation, and disconnection of staff skills. Specific examples are provided for each type of waste along with potential causes. Steps for waste elimination include motivation, just-in-time processes, correct automation, leveled scheduling, balanced workloads, quality inspection, line balancing, forecasting, and communication. Tools for waste reduction include visual controls, quick changeovers, cellular manufacturing, and total productive maintenance.
Overview of Lean and in Supply chain management and Warehouse distribution, identifying the value and NVA steps, streamlining the supply-distribution network to reduce warehouse storage, inventory and lead time
Lean manufacturing aims to eliminate waste through standard work and one-piece flow. Standard work establishes repeatable work sequences defined by operators. One-piece flow moves individual products continuously through processes to reduce wait time, lead time, and work-in-progress inventory. The benefits of one-piece flow include improved safety, quality, flexibility, productivity, and employee morale.
Lean thinking aims to remove wastes from processes by identifying any steps that do not add value for the customer. The original seven wastes are transportation, inventory, motion, waiting, overproduction, over-processing, and defects. An eighth waste of underutilized employee skills was later added. Each waste is examined, defining it and providing examples and countermeasures to reduce or eliminate it from processes.
The lean management initiative at Environs, a manufacturing company, failed for several reasons:
1) There was strong resistance to change from employees who were not involved in decision making and not provided support to implement new procedures.
2) A lack of timely and effective communication between shifts and management led to resentment and work difficulties.
3) Insufficient and discontinued training after 2 years left skills gaps, especially for new employees, undermining the sustainability of lean practices.
Lean production is an integrated approach that aims to eliminate waste. It includes techniques like just-in-time production and cell production. The goal is to receive goods and materials only as needed to maximize efficiency. Traditional production tends to overproduce and rely on large inventories while lean production focuses on minimizing waste and batch sizes. Key aspects of lean include continuous improvement, reducing set-up times, and eliminating bottlenecks and unnecessary processes.
The document provides an overview of lean manufacturing and production. It defines lean as eliminating waste to do more with less. The key aspects of lean covered include identifying the seven types of waste, implementing tools like 5S, just-in-time production, standard work, and continuous improvement. Lean requires minimizing overproduction, defects, inventory, motion, overprocessing, transportation, and waiting to achieve an efficient pull-based production system with stable workflow and engaged employees. The overall goal of lean is to deliver high quality products on demand with minimal costs and resources.
Presentation on Lean Manufacturing and waste eliminationshivithakur110
Lean manufacturing aims to maximize value and minimize waste in production. It was developed from Toyota's production system and focuses on eliminating non-value added activities. Key aspects of lean include identifying the value stream to reduce waste, using a pull system triggered by customer demand, cross-training employees to continuously improve processes, and implementing tools like 5S, standard work, and visual controls. The ultimate goal is to provide high quality, low cost products on time with minimal human effort, inventory, and space requirements.
Lean manufacturing aims to eliminate waste by focusing on value-added activities. It was developed based on the Toyota Production System and considers seven types of waste. Key Lean principles include specifying value from the customer perspective, making value flow without interruptions, and continuously improving processes through eliminating waste. Techniques like 5S, standard work, visual management, and value stream mapping are used to implement Lean.
Improve warehouse productivity - business breakfast sessionSukesh Ned
Sukesh Ned presents to Cumberland Business Chamber members how to optimise warehouse productivity via:
- industrial engineering techniques
- automated processes
- staff redeployment
and other techniques in April 2015
This document discusses lean manufacturing and its basic elements. Lean manufacturing aims to eliminate waste and reduce costs by focusing on continuous improvement, pull systems that minimize inventory, and reducing lead times. The key elements of lean manufacturing are pull systems that produce only to meet demand, reducing lead times through preventative maintenance and cell manufacturing, and continuous improvement through kaizen. The document outlines the seven types of waste lean aims to eliminate: overproduction, waiting, transportation, inappropriate processing, inventory, motion, and defects.
Lean production is a systematic method to eliminate waste from manufacturing. It identifies seven types of waste including transportation, inventory, unnecessary movement, waiting, overproduction, overprocessing, and defects. The key elements of lean production include flexible resources, cellular layouts, a pull system using kanbans, small lot sizes, quick changeovers, uniform production levels, quality at the source, and total productive maintenance. Implementing these elements can help reduce costs and inventory while improving quality, productivity, and flexibility. However, lean production requires steady demand and discipline.
The document summarizes the current issues with an electronics shop's layout and organization. Parts are scattered across multiple floors and areas, leading to lost time finding parts and unclear job flow. The goals are to decrease setup time by 50% through a more efficient layout and organized storage of parts and tools. Countermeasures proposed include centralized storage of parts in bins, clear labeling of job status, standardized wire and fastener inventory, and moving work stations to improve flow. Follow up items ensure the new processes are followed and the success of changes.
This document provides an overview of Lean fundamentals and tools. It discusses the history and evolution of manufacturing, the key principles of Lean thinking around value, value streams, flow, pull and perfection. It then describes the basic Lean tools for identifying and eliminating waste, including takt time, time observation, bar charts, spaghetti diagrams, standard work, visual management and pull systems. The goal of these tools is to optimize workflow, reduce waste and enable continuous improvement through establishing standard processes and engaging employees.
This document outlines how to implement the 5S methodology to organize and improve efficiency in a laboratory environment. The 5S system includes five phases: Sort, Set in Order, Shine, Standardize, and Sustain. Benefits of 5S include increased safety, employee involvement, organization, cleanliness, and space savings. Key aspects of implementation involve sorting necessary from unnecessary items, determining locations for necessary items, developing standard operating procedures, establishing performance measures, and sustaining practices through daily checklists and audits. Successful 5S requires commitment from all laboratory personnel.
Know about Just-In-Time and Lean manufacturing system. Find benefits and difference between JIT and Lean Manufacturing by Nilesh Arora, a founder of AddValue Consulting Inc.
- Learn a step-by-step description of an ideal approach to benchmarking.
- Why qualitative and quantitative benchmarking go hand-in-hand.
- Steps to setting up a benchmarking program
Presented by: Michael Mikitka, CEO, Warehousing Education & Research Council (WERC)
November 28, 2012 - Consumer Goods Supply Chain Officer Summit 2012 - Shanghai Pudong, China
The document provides an overview of lean office concepts including defining value from the customer's perspective, identifying value streams to reduce waste, using pull systems to optimize production to customer demand, and continuously improving processes to eliminate defects. It discusses benefits such as reduced costs, delivery times, and improved quality and customer satisfaction. Specific lean tools are outlined like 5S, visual controls, mistake proofing, quick changeovers, and using metrics like Six Sigma to measure and improve processes.
The document discusses Lean Production principles including eliminating waste, simplifying procedures, and speeding up production. It describes the seven types of waste targeted in Lean (overproduction, waiting, transportation, inventory, motion, over-processing, defective products). Benefits of Lean include reducing costs, lead times, inventory, and increasing quality and flexibility. Additional Lean tools discussed include Kaizen (continuous improvement), Poka-Yoke (mistake proofing), Kanban (pull system), and Jidoka (quality at source).
Applications of lean manufacturing toolsIshmam Ahmed
Lean Tools application with powerpoint animation. all processes are easily described with images & animation.
Uploaded by
Ishmam Ahmed
Industrial & Production Engineering (IPE)
Shahjalal university of science & Technology, Sylhet, Bangladesh
Lean manufacturing is a systematic method for waste minimization ("Muda") within a manufacturing system without sacrificing productivity.http://www.vpresentationslides.com/lean-manufacturing-ppt/
This presentation introduces lean manufacturing and identifies the eight types of waste. Lean manufacturing aims to eliminate waste through continuous improvement. The eight types of waste are overproduction, over processing, rework, waiting, excess inventory, excess motion, excess transportation, and disconnection of staff skills. Specific examples are provided for each type of waste along with potential causes. Steps for waste elimination include motivation, just-in-time processes, correct automation, leveled scheduling, balanced workloads, quality inspection, line balancing, forecasting, and communication. Tools for waste reduction include visual controls, quick changeovers, cellular manufacturing, and total productive maintenance.
Overview of Lean and in Supply chain management and Warehouse distribution, identifying the value and NVA steps, streamlining the supply-distribution network to reduce warehouse storage, inventory and lead time
Lean manufacturing aims to eliminate waste through standard work and one-piece flow. Standard work establishes repeatable work sequences defined by operators. One-piece flow moves individual products continuously through processes to reduce wait time, lead time, and work-in-progress inventory. The benefits of one-piece flow include improved safety, quality, flexibility, productivity, and employee morale.
Lean thinking aims to remove wastes from processes by identifying any steps that do not add value for the customer. The original seven wastes are transportation, inventory, motion, waiting, overproduction, over-processing, and defects. An eighth waste of underutilized employee skills was later added. Each waste is examined, defining it and providing examples and countermeasures to reduce or eliminate it from processes.
The lean management initiative at Environs, a manufacturing company, failed for several reasons:
1) There was strong resistance to change from employees who were not involved in decision making and not provided support to implement new procedures.
2) A lack of timely and effective communication between shifts and management led to resentment and work difficulties.
3) Insufficient and discontinued training after 2 years left skills gaps, especially for new employees, undermining the sustainability of lean practices.
Lean production is an integrated approach that aims to eliminate waste. It includes techniques like just-in-time production and cell production. The goal is to receive goods and materials only as needed to maximize efficiency. Traditional production tends to overproduce and rely on large inventories while lean production focuses on minimizing waste and batch sizes. Key aspects of lean include continuous improvement, reducing set-up times, and eliminating bottlenecks and unnecessary processes.
The document provides an overview of lean manufacturing and production. It defines lean as eliminating waste to do more with less. The key aspects of lean covered include identifying the seven types of waste, implementing tools like 5S, just-in-time production, standard work, and continuous improvement. Lean requires minimizing overproduction, defects, inventory, motion, overprocessing, transportation, and waiting to achieve an efficient pull-based production system with stable workflow and engaged employees. The overall goal of lean is to deliver high quality products on demand with minimal costs and resources.
Presentation on Lean Manufacturing and waste eliminationshivithakur110
Lean manufacturing aims to maximize value and minimize waste in production. It was developed from Toyota's production system and focuses on eliminating non-value added activities. Key aspects of lean include identifying the value stream to reduce waste, using a pull system triggered by customer demand, cross-training employees to continuously improve processes, and implementing tools like 5S, standard work, and visual controls. The ultimate goal is to provide high quality, low cost products on time with minimal human effort, inventory, and space requirements.
Lean Maintenance is gaining traction as a sound strategy to keep equipment running and productivity humming. The hardest part is getting started. On Thursday, March 20 at 1 p.m. CDT, Plant Engineering will present a Webcast that looks at the steps needed to implement a sound Lean Maintenance strategy on your plant floor and to begin to reap the benefits.
Learning objectives:
-The value of Lean Maintenance as a plant-floor strategy and the history of lean
-The steps and tools needed to get started down the road to Lean
-Getting plant-floor buy-in from line workers
-Incorporating technology into Lean maintenance
Lean manufacturing is a systematic approach to identifying and eliminating waste through continuous improvement by optimizing workflow and minimizing inventory. The main principles are reducing wait times, inventories, and batch sizes while ensuring production is pulled by customer demand. Lean focuses on getting the right things to the right place at the right time through techniques like just-in-time production, continuous improvement, worker empowerment, process optimization, and waste elimination. The ultimate goals are to improve quality, reduce costs and lead times.
1. Lean manufacturing focuses on eliminating waste throughout the production process through techniques like just-in-time production and pull systems.
2. A pull system controls production using signals like kanban cards to produce only what is needed and eliminates waste from long lead times and excess inventory.
3. The Toyota Production System pioneered lean techniques and its goals of continuously eliminating waste and improving processes while respecting people.
This document discusses lean production and operations principles for improving workplace performance. It begins by introducing the characteristics of a highly successful automaker known for quality, efficiency and profitability. It then outlines core lean principles like eliminating waste, just-in-time production, visual management and continuous improvement. Key lean elements are described in more detail like small lot sizes, quick changeovers, pull systems and supplier partnerships. Examples are provided of significant improvements in lead time, inventory, productivity and costs through lean implementation. Finally, it notes the importance of cross-functional teamwork and organizational learning to fully adopt lean approaches.
The document discusses pull manufacturing and lean principles. It explains that pull manufacturing links supply chain decisions and actions to minimize overhead through demand-driven production. Rather than pushing products through the system based on a schedule, pull scheduling uses visual triggers and kanban cards to pull products through production based on customer demand. This reveals problems and reduces waste and inventory compared to traditional push systems.
1. Visual control and management is an important tool in lean manufacturing to reduce errors, increase transparency, and build a culture of teamwork.
2. Visual controls like signs, charts, and color-coding are used to detect problems quickly and take corrective action to reduce waste and keep production on schedule.
3. Making information visible to all employees promotes shared understanding and involvement to continuously improve processes.
Lean manufacturing aims to eliminate waste in production processes. It was developed by Toyota and seeks to optimize value delivery through just-in-time production and continuous improvement. Key lean principles include specifying value, mapping the value stream, establishing smooth product flow, basing production on customer pull, and striving for perfection. Waste is eliminated using techniques like the 5S methodology and by addressing the 7 wastes. Lean can be applied to manufacturing as well as services.
Literature review - Data mining and Business Intelligence in ManufacturingAbhishek Nandgaonkar
Lean manufacturing is a production philosophy aimed at eliminating waste. It was developed from the Toyota Production System. The main types of waste are muda (non-value adding activities), muri (overburdening people or equipment), and mura (unevenness in workflow). Key aspects of lean include just-in-time production to reduce inventory waste, continuous improvement to reduce defects, and predictive maintenance to minimize downtime from equipment failures. Computer simulations can be used to compare the performance of traditional and sensor-based predictive maintenance policies on key metrics like system utilization, throughput, and total cost.
The document discusses principles for implementing lean manufacturing, including eliminating various types of waste like overproduction, defects, and transportation. It advocates for workplace organization using 5S principles like sorting, setting in order, sweeping, standardizing, and sustaining clean and organized work areas. Visual controls and standardized work processes are also recommended to clearly define work expectations and enable continuous improvement.
This document discusses lean operations management and various lean tools and methodologies. It begins by introducing lean operations management and some of its key tools, including 5S, SMED, Kaizen, Poka Yoke, Kanban, Andon, and card-based systems. It then provides more detailed explanations of 5S methodology, including its five pillars of Sort, Set in Order, Shine, Standardize, and Sustain. It discusses how 5S provides the foundational elements for implementing other lean tools and techniques. It also discusses how 5S principles of cleanliness and organization can help during a pandemic by reducing the spread of infection.
This document provides an overview of key concepts from a university course on lean thinking and operations management. It defines lean as eliminating waste through the involvement of all employees and continuous improvement. The Toyota Production System is discussed as a seminal example of lean. Key lean principles are reducing inventory, stopping problems at their source, producing only what is needed when it is needed, and continuously improving processes. Various lean tools like visual management, kanban systems, and setup reduction are also outlined. The document emphasizes that lean is a philosophy as well as a set of techniques for eliminating waste from operations.
Lean manufacturing aims to eliminate waste from production processes. It was developed by Toyota and seeks to create value for customers through principles like specifying value, optimizing flow, and continuously improving processes. Key aspects of lean include identifying the value stream, eliminating seven types of waste, and using the 5S methodology to organize the workplace.
Lean operations aim to remove all non-value adding activities to deliver a faster, more dependable, higher quality and lower cost operation that is more responsive to customers. Just-in-time means producing goods exactly when needed to avoid inventory waste. The lean philosophy focuses on eliminating waste, involving everyone, and continuous improvement. Key lean techniques include visual management, small batch production, pull scheduling, total productive maintenance, and design for manufacturability. Lean and MRP planning approaches can be combined if their advantages are understood and preserved.
Toyota Production System or Lean Manufacturing has become an imperative to sustain the current hyper competitive scenario . This presentation looks at the basic tenets of Lean Manufacturing as a philosophy as well as a practicing regime.
This document provides an agenda for a program on enhancing productivity and product quality through Lean Six Sigma. The program schedule is laid out over four sessions covering topics like Lean manufacturing, Six Sigma, 5S, TPM and more. The document discusses various Lean tools and concepts like value stream mapping, takt time, poka-yoke and how they can help reduce waste and improve key metrics like OEE. Overall, the program aims to equip participants with knowledge and techniques to improve efficiency, quality and profits through continuous improvement.
The document provides an overview of AFSO21 (Air Force Strategic Operations for the 21st Century), which is the Air Force's methodology for continuous process improvement using lean principles. It discusses the history and principles of lean, defines waste, and explains tools like standard work, 6S, and problem solving. It also gives examples of process mapping and describes what an AFSO21 process improvement event would entail. The goal of AFSO21 is to eliminate waste, reduce costs and response times, and improve productivity across the Air Force.
Part 2 Deep Dive: Navigating the 2024 Slowdownjeffkluth1
Introduction
The global retail industry has weathered numerous storms, with the financial crisis of 2008 serving as a poignant reminder of the sector's resilience and adaptability. However, as we navigate the complex landscape of 2024, retailers face a unique set of challenges that demand innovative strategies and a fundamental shift in mindset. This white paper contrasts the impact of the 2008 recession on the retail sector with the current headwinds retailers are grappling with, while offering a comprehensive roadmap for success in this new paradigm.
How are Lilac French Bulldogs Beauty Charming the World and Capturing Hearts....Lacey Max
“After being the most listed dog breed in the United States for 31
years in a row, the Labrador Retriever has dropped to second place
in the American Kennel Club's annual survey of the country's most
popular canines. The French Bulldog is the new top dog in the
United States as of 2022. The stylish puppy has ascended the
rankings in rapid time despite having health concerns and limited
color choices.”
Storytelling is an incredibly valuable tool to share data and information. To get the most impact from stories there are a number of key ingredients. These are based on science and human nature. Using these elements in a story you can deliver information impactfully, ensure action and drive change.
The Steadfast and Reliable Bull: Taurus Zodiac Signmy Pandit
Explore the steadfast and reliable nature of the Taurus Zodiac Sign. Discover the personality traits, key dates, and horoscope insights that define the determined and practical Taurus, and learn how their grounded nature makes them the anchor of the zodiac.
Zodiac Signs and Food Preferences_ What Your Sign Says About Your Tastemy Pandit
Know what your zodiac sign says about your taste in food! Explore how the 12 zodiac signs influence your culinary preferences with insights from MyPandit. Dive into astrology and flavors!
Best Competitive Marble Pricing in Dubai - ☎ 9928909666Stone Art Hub
Stone Art Hub offers the best competitive Marble Pricing in Dubai, ensuring affordability without compromising quality. With a wide range of exquisite marble options to choose from, you can enhance your spaces with elegance and sophistication. For inquiries or orders, contact us at ☎ 9928909666. Experience luxury at unbeatable prices.
Top mailing list providers in the USA.pptxJeremyPeirce1
Discover the top mailing list providers in the USA, offering targeted lists, segmentation, and analytics to optimize your marketing campaigns and drive engagement.
Profiles of Iconic Fashion Personalities.pdfTTop Threads
The fashion industry is dynamic and ever-changing, continuously sculpted by trailblazing visionaries who challenge norms and redefine beauty. This document delves into the profiles of some of the most iconic fashion personalities whose impact has left a lasting impression on the industry. From timeless designers to modern-day influencers, each individual has uniquely woven their thread into the rich fabric of fashion history, contributing to its ongoing evolution.
HOW TO START UP A COMPANY A STEP-BY-STEP GUIDE.pdf46adnanshahzad
How to Start Up a Company: A Step-by-Step Guide Starting a company is an exciting adventure that combines creativity, strategy, and hard work. It can seem overwhelming at first, but with the right guidance, anyone can transform a great idea into a successful business. Let's dive into how to start up a company, from the initial spark of an idea to securing funding and launching your startup.
Introduction
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1. Industrial Solutions - ISI www.isiworld.net
Lean Warehouse 101
w/ Live Simulation
Standardized Work Batch Reduction Teams
Quality at Source
5S System Visual Controls Facility Layout
POUS (Point of Use Storage)
Level FlowPull / Kanban
Culture of
Continuous Improvement
Value
Stream
Mapping
2. Industrial Solutions - ISI www.isiworld.net
Welcome
• Introduce the instruction team
• What is Industrial Solutions?
• What is the role of the Technology Center
• About the facility
• Ground rules for the class
3. Industrial Solutions - ISI www.isiworld.net
Course Agenda
Welcome
Introduction to Simulation
Round 1 of Simulation
Introduction to Lean Manufacturing, 8 Wastes
Standardized Work, 5S System, Visual Controls, Facility Layout,
BatchReduction, Teams
Round 2 of Simulation
POUS, and Quality at the Source, Pull/Kanban
Round 3 of Simulation
Implementation
Wrap up
5. Industrial Solutions - ISI www.isiworld.net
Recommended Readings
Lean Thinking
by Jim Womack
Becoming Lean
by Jeffrey Liker
Toyota Kata
by Mike Rother
The Toyota Way & Toyota Talent
by Jeffrey Liker
Building a Lean Fulfillment Stream
by Robert Martichenko & Kevin von Grabe
Lean in Warehousing
by David Graham and Manny Cantone
Everything I Know About Lean I learned in First Grade
by Robert Martichenko
6. Industrial Solutions - ISI www.isiworld.net
Today’s training with simulation will
• Provide basic lean training
• Show key principles for improving warehousing
operations
• Let us ‘learn by doing’
• Experience the improvements that Lean Thinking
can make in a warehousing operation
We may discover some solutions for some of your
company’s current problems.
7. Industrial Solutions - ISI www.isiworld.net
Reduced Lead Time
“One of the most noteworthy accomplishments in
keeping the price of Ford products low is the
gradual shortening of the production cycle. The
longer an article is in the process of manufacture (or
in distribution) and the more it is moved about, the
greater is its ultimate cost.”
— Henry Ford, 1926
8. Industrial Solutions - ISI www.isiworld.net
Lean Is Market Driven
Every morning in Africa, a gazelle wakes up. It
knows it must run faster than the fastest lion or it will
be killed. Every morning a lion wakes up. It knows it
must outrun the slowest gazelle or it will starve to
death.
It doesn’t matter whether
you are a lion or a gazelle
— when the sun comes
up, you had better be
running.
9. Industrial Solutions - ISI www.isiworld.net
Defining Lean
Lean is:
“A systematic approach to identifying and
eliminating waste (non-value-added activities)
through continuous improvement by flowing the
product at the pull of the customer in pursuit of
perfection.”
— The MEP Lean Network
10. Industrial Solutions - ISI www.isiworld.net
Simple Lean:
Developing People
Eliminate Waste
Creates Flow
Satisfies the Customer
To see and
which
that
11. Industrial Solutions - ISI www.isiworld.net
Definition of Value-Added
Value-Added
Any activity that
increases the market form
or function of the product
or service. (These are
things the customer is
willing to pay for.)
Non-Value-Added
Any activity that does not
add market form or
function or is not
necessary. (These
activities should be
eliminated, simplified,
reduced, or integrated.)
12. Industrial Solutions - ISI www.isiworld.net
Ways we experience Waste:
• Incomplete/late data
• Inaccurate data
• Rushed work
• Insufficient training
• Misplaced
• Poor layout
• No Standard Work
• Count errors
• Priority- Hot Order
• Starting-stopping Work
• Typo
• Can’t Read
• Equipment Problems
• Technology Issues
• Insufficient Stock
• Old Stock
• Damaged Stock
• Too Much Paperwork
13. Industrial Solutions - ISI www.isiworld.net
Lean = Eliminating Waste
Typically 95% of all lead time is non-value-added.
Value-Added Non-Value-Added
• Overproduction
• Waiting
• Transportation
• Processing
• Excess inventory
• Errors
• Excess motion
• Underutilized people
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Work Place Organization
A safe, clean, neat arrangement of the workplace
provides a specific location for everything, and
eliminates anything not required.
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Facility Layout
• Causes of waste:
- Unfavorable facility or shelf / floor layout
- Poor workplace organization and housekeeping
- Not organized to flow product easily through
- Misunderstood work flow for moving product
- Lengthy distances and excessive effort to
accomplish work
- Poor lighting and air handling
**Your pick path will become more predictable if
you have good storage design with less cycle time
variation in your work tasks.
16. Industrial Solutions - ISI www.isiworld.net
Standardized Work
Operations safely carried out with all tasks organized
in the best known sequence, and using the most
effective combination of these resources:
• People
• Materials
• Methods
• Machines
A STABLE PROCESS MUST EXIST BEFORE
IMPROVEMENTS CAN BE MADE!!!!!!!!!!!!
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Management’s Role Changes
• Management becomes significantly present on the
work floor
• Their roles shift from being problem solvers to that
of coaches, teachers, and mentors to their team.
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Batch and Queue Processing
Impact of Order Numbers Picked Reduction
10 min.
30+ min. for total order, 21+ min. for first piece
Find-Pull
10 min.
Count-
Repack
Consolidate
10 min.
Count-
Repack
Find-Pull Consolidate
Continuous
Flow
Processing
12 min. for total order,
3 min. for first part
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Lean Workforce Practices
• Teams
- with rotation of highly specified jobs
• Cross-trained and multi-skilled employees
- who can work many operations within the
warehousing processes
• Continuous improvement philosophy; Problem-
solving
• Process quality, not inspection
• Use of participatory decision-making
- team-based problem-solving, suggestion
systems, Kaizen events, etc.
20. Industrial Solutions - ISI www.isiworld.net
Point Of Use Storage (POUS)
• Parts are stored at / near where packed
• Works best if vendor relationship (Collaboration)
permits frequent, on-time, small shipments
• Simplifies physical inventory tracking, storage, and
handling
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Quality @ Source
• Embrace the golden rule of ‘quality at the source’ and mistake
proofing in a lean warehouse!
• Errors are just mistakes –
- 1. Never make one
- 2. Never take one, but if you do…
- 3. Never pass one on.
The empowering message to team members is… we all own
our work! It’s my job to do it correctly the 1st time.
22. Industrial Solutions - ISI www.isiworld.net
Push versus Pull Systems
Push System
Resources are provided
to the consumer based
on forecasts or
schedules.
Pull System
A method of controlling
the flow of resources by
replacing only what has
been consumed.
23. Industrial Solutions - ISI www.isiworld.net
Pull System
Pull System is a flexible
and simple method of
controlling or balancing
the flow of resources
Eliminating waste of
handling, storage,
expediting,
obsolescence, repair,
rework, facilities,
equipment, excess
inventory
Pull System consists of:
• Production based on
actual orders
• Small lots
• Low inventories
• Management by sight
• Better communication
24. Industrial Solutions - ISI www.isiworld.net
Lean Building Blocks
Standardized Work Batch Reduction Teams
Quality at Source
5S System Visual Controls Facility Layout
POUS (Point of Use Storage)
Level FlowPull / Kanban
Culture of
Continuous Improvement
Value
Stream
Mapping
25. Industrial Solutions - ISI www.isiworld.net
Continuous Improvement
Old Adage:
“If you always do what you always did, you’ll
always get what you always got.”
Competitive Corollary:
“If the other guy gets better, you’re going to get
less.”
26. Industrial Solutions - ISI www.isiworld.net
Bridge Analogy
• The idea is to push your people and the organization across
that bridge as quickly as possible to get to the new way of
thinking and doing the work.
• Then burn the bridge, so there is no way of going back. There
are going to be transition challenges.
• Your goal is to pass through those challenges as quickly as
possible.
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Barriers to Improvement
If we all know we need to improve, the question
becomes: why don’t we?
F
E
A
R
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Simply put:
Our Daily Job is:
- Follow standard work at all times
- Continually improve upon that standard
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Benefits of Lean
Lead Time Reduction
0 25 50 75 100
Percentage of Benefits Achieved*
Productivity Increase
WIP Reduction
Quality Improvement
Space Utilization
*Typical Benefits of Lean after 2 years of implementation.
30. Industrial Solutions - ISI www.isiworld.net
Typical Objections Excuses
How should you deal with these objections to Lean?
• “It takes too much discipline.”
• “It takes too long to implement.”
• “My process is too complex, I have to deal with
too many uncontrollable variables; late supplier
shipments, sick people, quality issues, etc.”
• “My process requires picking a large batch of
orders.”
• “It doesn’t make sense in my industry.”
• “It’s unclear to me how Lean will work with my
MRP system.”
31. Industrial Solutions - ISI www.isiworld.net
Conclusion
Contrast between Lean & Status Quo
Lean
• Simple and visual
• Demand driven
• Inventory as needed
• Reduce non-value-added
• Single order processing
• Minimal lead time
• Lower ‘Total Cost’
• Flexible Customer Service
Traditional
• Complex
• Forecast driven
• Excessive inventory
• Speed up value-added work
• Multiple order processing
• Long lead time
• Lowest cost purchased price
• Optimized processes individually