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Ten Steps to Lean Production

Ten Steps to Lean Production. Steps to CIM. Re-engineer (revisit, replan) the manufacturing system Form U-cells to produce families of parts (clusters) Integrate production, inventories, Quality Control and machine tools. Steps to CIM. Setup reduction or elimination

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Ten Steps to Lean Production

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  1. Ten Steps toLean Production

  2. Steps to CIM • Re-engineer (revisit, replan) the manufacturing system • Form U-cells to produce families of parts (clusters) • Integrate production, inventories, Quality Control and machine tools

  3. Steps to CIM • Setup reduction or elimination • Identify elements that are “internal” and those that are “external” • Improve methods (use a pit crew) • Re-engineer to eliminate adjustments, mechanize, automate

  4. Steps to CIM • Integrate quality control into the system • Develop a systems approach • Incorporate visual signals • Work toward a “1 piece flow” Make 1, check 1, move 1 on

  5. Steps to CIM • Integrate preventative maintenance into the system • Reduce pressure on workers and the process (back off from 100%) • Housekeeping – place for everything and everything in place • Decrease system variability

  6. Learning Loops in CIM

  7. Steps to CIM • Level, balance, sequence and synchronize • “Smooth” manufacturing • Keep production “level” • Make production “predictable” • Incorporate “kanban” labelling Label

  8. Steps to CIM • Production Control • Integrate scheduling and control functions into the system • Use MRP/ERP software • Use the PC system to link cells together • MRP = Manufacturing • ERP = Enterprise • DRP = Distribution • CRP = Capacity • BRP = Business

  9. Schematic factory layout

  10. Steps to CIM • Reduce work-in-process • Excess inventories hide problems • Reduce the inventory to expose problems • Take immediate action to eliminate the problems

  11. Steps to CIM • Integrate suppliers • Work to reduce suppliers to a single source • Develop trust & open communications • Implement flexible procurement (supply purchasing) contracts • Develop long-range forecasts

  12. Steps to CIM • Automation • Allow workers to control the process (trust in work force) • Provide clear directions • In-process controls and inspections • Feedback loops

  13. Steps to CIM • Computer-Integrated Manufacturing • Enterprise-wide systems • Remove functionality (independence) of departments • Focus teams on product lines and customers

  14. The REAL Goal is to become LEAN • Waste eliminated • Employees involved • Customers satisfied • Profits increased • Company survival assured By printing and binding in the same factory, Butler and Tanner reduces the amount of transport required during the production process

  15. Achieving CIM • Toyota has been on a “journey” toward a waste free and coordinated operation for 45 years… and they know they are not there yet. • The “steps” and “tools” help people understand the process of change, but there is much more that is required

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