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worldofsteelLean Culture Introduction
What Is Lean?                    Respect for                      People    Remove                                    Star...
The Seven WastesTransportation     Inventory          Motion        Wait time         Over Processing     Over Production ...
Continuously                     Improve Muda = Waste Mura = Flow Muri = Respect  for People Continue to  tackle all o...
Traditional             Lean enterprise           Emphasis on production        Emphasis on customer service          Make...
Think Like a                 Lean Culture1) Leadership2) Visual Controls3) Feedback4) Do What You Say   – Say What You   D...
Leadership Strategic  Alignment Daily Standard  Work Gemba Walks
Visual                      Controls Visuals to help  prevent errors Data about  process is easy  to see A 3rd grade le...
Feedback Instantaneous  feedback Corrective action  close to  instantaneous Project  management  done in a visual  way
Do What You                  Say – Say What                      You Do All processes are  up-to-date in the  paper work...
Root Cause                       Problem Solving No more band  aids and  firefighting Use tools like  FEMA(Failure  Mode...
Results Computer Re-manufacturing    Quality - 75% improvement    Productivity - 25% improvement    Cycle Time - 50% i...
Lean Mangement
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Lean Mangement

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Lean Mangement

  1. 1. worldofsteelLean Culture Introduction
  2. 2. What Is Lean? Respect for People Remove Start Now Waste Continuously Flow Improve
  3. 3. The Seven WastesTransportation Inventory Motion Wait time Over Processing Over Production DefectsMovement between Buffers Poor work Materials Excessive testing Material Shortages Internalbuildings/sites design Shortages Excess WIP & Install Un-level Demand ReworkPremium RIP Ergonomic Un-level Demandfreight Design Reconfiguration Build to stock Supplier Supplier StartupDistribution inventories for Travel time Double handling Economic Lot Sizes Final TestNetwork long lead time Vendor Tool & Predictability Material Batching InspectionPlant Layout Stock Material variability/over access Scheduling design Conflicts Operations, Overhead, Materials, Suppliers
  4. 4. Continuously Improve Muda = Waste Mura = Flow Muri = Respect for People Continue to tackle all of these areas to keep your Lean System going
  5. 5. Traditional Lean enterprise Emphasis on production Emphasis on customer service Make product to forecast Makes to actual customer demand ‘Push’ production system ‘Pull’ production system Machine utilization Employee utilizationReduce cost and increase efficiency Reduce waste and add valueLeadership by executive command Leadership by vision and broad participation Specialized employees Multi-functional employees Penalize mistakes Educate Blame people Identify and solve process failure Reactive Proactive Inspect in Quality Built in Quality Complexity Simplicity Functional Management Structure Manage by Value Stream How does your company rate as a Lean Rating Scale: 1 2 3 4 5 Enterprise?
  6. 6. Think Like a Lean Culture1) Leadership2) Visual Controls3) Feedback4) Do What You Say – Say What You Do5) Stick To The Process6) Root Cause Problem Solving7) Continuous Improvement
  7. 7. Leadership Strategic Alignment Daily Standard Work Gemba Walks
  8. 8. Visual Controls Visuals to help prevent errors Data about process is easy to see A 3rd grade level
  9. 9. Feedback Instantaneous feedback Corrective action close to instantaneous Project management done in a visual way
  10. 10. Do What You Say – Say What You Do All processes are up-to-date in the paper work Ask anyone and they will give you the same response Supposed to = Actual
  11. 11. Root Cause Problem Solving No more band aids and firefighting Use tools like FEMA(Failure Mode And Effect Analysis), fishbon e diagrams, and Gemba to solve root cause Processes reveals problems easily
  12. 12. Results Computer Re-manufacturing  Quality - 75% improvement  Productivity - 25% improvement  Cycle Time - 50% improvement  Total Cost - 42% reduction Computer Manufacturing  Quality - 98% improvement  Productivity - 12.5% improvement  Cycle Time - 50% improvement  Total Cost - 31% reduction Veterinary Clinic – 30% Improvement in Revenue

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