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Lean Manufacturing. Chapter 15 pp. 438-466 June 29, 2012. Lean Manufacturing. Definition Elimination Waste Continuous improvement 3 pronged approach “Relentless” focus on quality Eliminate waste Involve employees. Lean Manufacturing.
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Lean Manufacturing Chapter 15 pp. 438-466 June 29, 2012
Lean Manufacturing • Definition • Elimination • Waste • Continuous improvement • 3 pronged approach • “Relentless” focus on quality • Eliminate waste • Involve employees
Lean Manufacturing • “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.”
Lean Manufacturing • Key principles • Value • Value stream • “mapping” • Flow • Pull • Perfection • culture
Lean Manufacturing • Benefits • Lead time reduction • WIP reduction
45 minutes 14 days 1 day 60 minutes 30 minutes 2 days 1 day
Lean Manufacturing • Benefits • Lead time reduction • WIP reduction • Quality improvement • Space utilization • Greater customer satisfaction
“A systematic approach to identifying and eliminating….” • Value stream mapping
“A systematic approach to identifying and eliminating….” • Value stream mapping
“…waste (non-value added activities) …” • 8 wastes of lean • Overproduction • Inventory • Waiting • Defects • Extra processing • Excessive motion • Transportation • Underutilized employees
“…waste (non-value added activities) …” • 8 wastes of lean • Overproduction • Inventory • Transportation • Excessive motion • Extra processing • Defects • Waiting • Underutilized talents
“non-value added activities” • Value-added activities • Transforms or shapes material or information • Customer wants it • Done right the first time • Machining • Assembly • Painting • Sewing
“non-value added activities” • Non-value added activities • Consume resources but create no value for customers • Could be stopped and it would be invisible to the customer
“…through continuous improvement…” • kaizen • Satisfying the customer • People = most important resource • Quality at the source
“…through continuous improvement…” • 5S’s • Sort • Stabilize (set in order) • Shine • Standardize • Sustain
Stability • Traditional layout • Cellular layout
1 2 3 4 5 Lathe Drill Mill Mill Inspect 27 Seconds 27 Seconds 6 27 Seconds Drill 10 9 8 7 Pack Inspect Drill Test Stability
“…by flowing the product at the pull of the customer…” • Just-in time • Pull system (vs push) • Quick changeover (Set-up Reduction)
“…by flowing the product at the pull of the customer…” • Pull system • Production based on actual consumption • Small lots • Low inventories • Management by sight • Better communication
Pull System • Kanban
Pull System • Kanban • Supermarket
Quick Changeover (Set-up Reduction) Single minute exchange of dies (SMED)
Quality at the Source • Source inspection • Means to inspect • Samples or established standards • Process documentation • Mistake proofing
Quality at the Source • Source inspection • Means • Samples or established standards • Process documentation • Mistake proofing • Andon
Standardization • Standardized work
Involvement • Teams • with rotation of highly specified jobs • Cross trained/multi-skilled employees • can work many operations within a cell and operations in different cells
1 2 3 4 5 Lathe Drill Mill Mill Inspect 27 Seconds 27 Seconds 6 27 Seconds Drill 10 9 8 7 Pack Inspect Drill Test Stability
Involvement • Teams • with rotation of highly specified jobs • Cross trained/multi-skilled employees • can work many operations within a cell and operations in different cells • Continuous improvement philosophy • Process quality, not inspection • Use of participatory decision making
Why do it? • Reduced inventory • Improved quality • Lower costs • Shorter lead time • Increased productivity • Greater flexibility • Greater customer satisfaction
Last comment • Lean and Six Sigma • “hand and glove”