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WHAT IS LEAN
- 1. Quality Purchasing FinanceJ&J S&N SalesShipping YouIT HR CEO Quotes by Shigeo Shingo, industrial engineer and Toyota Production System Lean expert. 8 Wastes of Lean LEAN = YOU + ALL OF MANGAR Defect Work that contains errors or lacks something necessary. Does not meet acceptance criteria Overproduction Producing more materials or information than customer demand calls for Waiting Idle time created when material, information, people, or equipment is not ready Not Utilizing Talent Not, or under utilizing the talent of employees Transportation Movement of materials or information that does not add value Inventory Excess materials on hand that customers or employees do not need right now Motion Movement of people that does not add value Extra Processing Non value added processing OFFICE WASTE • Incorrect information being shared • Data entry errors • Forwarding incomplete documents • Creating reports no one needs/reads • Making extra copies • Providing more information than needed • Ineffective meetings • Waiting for meetings to start • Files awaiting signature of approvals • Insufficient training • High absenteeism and turnover • Inadequate performance • Hand carrying paper to the next process • Delivering unneeded documents • Going to get signatures • Purchasing excessive office supplies • Searching for computer files • Obsolete files or office equipment • Searching for files • Walking / reaching to get materials • Sifting through inventory to find what is needed • Unnecessary signatures on a document • Making more copies of a document than will be needed • Saving multiple copies of the same file in multiple locations MANUFACTURING WASTE • Scrap • Rework • Missing parts • Producing more product than demand • Batch process resulting in extra out-put • Having a “push” production system • Waiting for tools, parts, information • Broken machines waiting to be fixed • Raw materials not ready • Employing people in the wrong position • Not fully training employees • Missing improvements by failing to listen to employees • Moving products around before shipping • Moving product from different work stations • Moving inventory around to take stock • More finished product than demand • Extra materials taking up work space • Broken machines sitting around • Reaching to make adjustments • Walking to get a tool multiple times • Repetitive movements that could overwork / injure an employee • Adding unneeded value to a product • Using a more high tech machine than needed • Extra steps to correct avoidable mistakes DEVELOPMENT WASTE • Lack of attention to detail • Poorly written code • Inadequate documentation • Developing extra features • Duplicating effort • Documentation with more detail than required • Waiting for time zones • Systems unavailable • Insufficient skills for the task • Assign staff to wrong tasks • Wasteful admin tasks • Poor planning • Outsourcing work that is best done in-house • Hand-offs between teams • Endless emails • Partially done work • Unfinished testing • Incomplete documentation • Constantly switching tasks • Ineffective prioritization • Travel between offices • Poor tools creating delays • Retesting • Relearning A systematic approach that allows Mangar to deliver: Þ LOW COST PRODUCTS Þ SHORTEST LEAD TIME Ý HIGH QUALITY through the relentless elimination of “waste” What is Lean and why do it?reduce, or eliminate waste increase customer value Research & Development What is Waste? Any task or activity that does not add direct value to the end service or product from the customer’s perspective. Lean has 8 Wastes. Remember them by D.O.W.N.T.I.M.E. Manufacturing