Lean Manufacturing Training by liaoqinmei

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									    Lean
Manufacturing
  Overview


   Common Sense Services, LLC
      What is
Lean Manufacturing?




      Common Sense Services, LLC
     Lean Manufacturing
       What It’s Not …
• Program of the Month
• Quick Fix . . . Short Cut
• Method of Eliminating People
• Just a Method of Controlling Inventory
• Just for Manufacturing


               Common Sense Services, LLC
    Lean Manufacturing
         Definition

    Improving Productivity
to better satisfy your Customers
      while reducing Cost

through   Elimination of Waste

             Common Sense Services, LLC
 Lean Manufacturing
               Standardized
ONE WAY          Capable
                   Repeatable
                     Processes




          Common Sense Services, LLC
         Lean Manufacturing
• Requires that Resources be used in concert
  with Customer Demand which is usually not
  at Top Speed
• Emphasizes utilizing people to their fullest
  potential, requiring cooperation, planning,
  understanding and involvement
• The Cornerstone of Lean is Simplicity,
  Visibility, Flexibility and Responsiveness vs.
  complicated, hidden, inflexible, and slow
• Requires and becomes Continuous Change
              (Continuous Improvement)
                    Common Sense Services, LLC
Lean Manufacturing Objective

It’s all about balancing the Flow of
     Money
        Method
           Materials
               Man
                   Machine

               Common Sense Services, LLC
 Lean Manufacturing Results
            FEDERAL RESERVE NOTE
      THE UNITED STATES OF AMERICA
100                                   100
        G
                            100
100                                   100
      ONE HUNDRED DOLLARS

            THE GOAL
          is PROFIT
                 Common Sense Services, LLC
Lean Manufacturing




      Common Sense Services, LLC
Leadership Creates The
    Environment




        Common Sense Services, LLC
Lean requires making Change
         “Why do people
         resist change?”
Oh No!                           Ahhh!




           Common Sense Services, LLC
Lean requires Understanding

      Change          Implement



                              Measure
Develop




                   How do I ....
               Common Sense Services, LLC
Lean is a Learning Process
   Learning Process

HEAR
        SEE
                  DO

         Common Sense Services, LLC
 We Learn, We Understand
• 10% of What We Hear

• 15% of What We See

• 20% of What We Both See and Hear

• 40% of What We Discuss With Others

• 80% of What We Do or Practice

• 90% of What We are Able to Teach Others

              Common Sense Services, LLC
We Learn, We Understand
                              I Forget      ?
         I Hear




                              I Remember
          I See                             Vision




 Learn
   By
Change
 I Do
                             I Understand



                  Common Sense Services, LLC
                   Lean Organization
           Total Organizational Involvement
                             Business Planning
        Personnel              Voice of the                   Materials
                                Customer                     Management
                                                   Distribution
             Marketing                              Network

I.T.    Design             LEAN                        Sales/Service
                        ORGANIZATION
                 Engineering                  Manufacturing
                 • Product
                 • Process                     & Assembly
                 • Tooling
                                                              Public
       Financial                  Suppliers                  Relations
                             Quality/Reliability


                                Common Sense Services, LLC
  Identification
and Elimination of
     Waste

      Common Sense Services, LLC
What is “Lean”, what is Waste ???

  •   The lowest Inventory ?
  •   The least Manpower ?
  •   The fewest Hours per Finished Product ?
  •   The most Inventory Turns ?
  •   The highest Value-Added Content ?
  •   The shortest, quickest Value Stream ?




                    Common Sense Services, LLC
What is “Lean”, what is Waste ???

  •   The lowest Inventory ?
  •   The least Manpower ?
  •   The fewest Hours per Finished Product ?
  •   The most Inventory Turns ?
  •   The highest Value-Added Content ?
  •   The shortest, quickest Value Stream ?




                    Common Sense Services, LLC
“Lean” is …

 Providing
    High Quality
        Customer Responsive
    Products     &   Services
                     at a Low Cost



             Common Sense Services, LLC
“Lean” involves …


Identification & Elimination
              of
            Waste



           Common Sense Services, LLC
“Lean” involves …


Identification & Elimination
              of
            Waste



           Common Sense Services, LLC
What causes most Waste ?
    VARIATION
       - Demand
          - Quantity
          - Frequency
       - Process
          - Capability
          - Repeatability
          - Reliability
       - Lot/Batch Sizes
          - Delivery
          - Production

         Common Sense Services, LLC
7 Types of Waste




     Common Sense Services, LLC
     7 Types of Waste

Here’s an acronym to help remember:




             Common Sense Services, LLC
     7 Types of Waste

Here’s an acronym to help remember:


  COMMWIP


             Common Sense Services, LLC
        7 Types of Waste

   Here’s an acronym to help remember:


     COMMWIP
How to COMMunicate Waste In Processes



                Common Sense Services, LLC
    7 Types of Waste

Correction
  Over production
     Motion
        Movement
          Waiting
           Inventory
              Process
         Common Sense Services, LLC
              7 Types of Waste

                  Correction
• Repairing, Reworking, Replacing Defective Items
• Inspection – you can’t inspect in quality
• Scrap – creates three times the original cost




                      Common Sense Services, LLC
              7 Types of Waste

             Over Production
• Producing more than needed
• Making parts too soon, before needed
• Building large quantities in batches




                      Common Sense Services, LLC
              7 Types of Waste

                    Motion
• Excessive walking, reaching, bending
• Picking up, setting down, re-positioning
• Fire-fighting, hurrying, no standard work




                     Common Sense Services, LLC
              7 Types of Waste

                 Movement
• Moving one item to get another
• Multiple storage locations for same item
• Traveling long distances around obstacles




                     Common Sense Services, LLC
              7 Types of Waste

                    Waiting
• Operators waiting to perform tasks
• Parts waiting for next operation
• Not having right tools or info when needed




                     Common Sense Services, LLC
              7 Types of Waste

                   Inventory
• More parts and items than necessary
• Unable to find what is needed, lost in a pile
• Not enough space to keep everything




                      Common Sense Services, LLC
              7 Types of Waste

                    Process
• Extra steps or motions adding no real value
• Using automation for simple processes
• Expensive high speed machines
     for low demand, slower need items


                     Common Sense Services, LLC
7 Types of Waste




     Common Sense Services, LLC
         7 Types of Waste


   Here’s an acronym to help remember:


     COMMWIP
How to COMMunicate Waste In Processes



                Common Sense Services, LLC
 Waste Walk
Floor Exercise



    Common Sense Services, LLC
Common Sense Services, LLC
Creating
 Flow


 Common Sense Services, LLC
Fitting the Pieces Together


       LEAN
      Principles




      Common Sense Services, LLC
     Keeping the Vision in Mind

• Understanding the Connections between the
  Principles
• Using the best Principles to fit current
  conditions
• Being able to see when conditions change
• Knowing when you’re still on track
• Getting answers or ideas to issues you uncover
• Recognizing the “rocks” restricting Flow
• Determining if you’re getting expected results


                    Common Sense Services, LLC
            Key Principles


• Reduce or Remove sources of Variation

• Create Standardized Work

• Implement Small Lots

• Increase Frequency




                  Common Sense Services, LLC
                  Inventory




Common Sense Services, LLC
    Inventory hides PROBLEMS




PROBLEM               PROBLEM



  HIDDEN                EXPOSED
            Common Sense Services, LLC
     A Lean Material Flow Process

•   Must be a capable repeatable process
•   Must have a process for handling emergencies
•   Must be able to identify when problems exist
•   Must include a problem resolution process
     with a plan for:
         – a short term quick fix, and
         – a root-cause long term solution




                       Common Sense Services, LLC
                   Creating Flow
1. Begin with the “Customer”, work towards the “Supplier”
2. Start with Final Assembly Operator
3. Determine what they need, where items fit
4. Develop best method to get items there
5. Decide delivery process and frequency
6. Establish where to get items from
7. Layout any storage areas to support picking items
8. Determine size of storage needed based on variation
9. Reduce process variation to reduce the amount stored
10.Increase frequency into and out of storage area to create Flow

                          Common Sense Services, LLC
   A Lean Material Flow Process
                            MUST
                      Support the Operator

• Reduce Waste in the Process
  –   reaching
  –   walking
  –   waiting
  –   getting ahead

• Allow for display of parts directly to operators
• Provide the ability to deliver more parts
  per delivery to more customers

                          Common Sense Services, LLC
     Implementation Issues

• Data Collection
• Data Integrity
• System Support
  – Data Download
  – Data Upload
• Process Measurements
• Management Commitment and Support



                    Common Sense Services, LLC
          Transition to Flow

• How do we get there ?
  –   Perform adequate planning
  –   Understand Process capability & constraints
  –   Identify and fix problems
  –   Implement small lots,
            with more frequent movement
  –   Enforce standardized processes
  –   Control floor operations Visually

  –   Build on our learnings, yours and others


                   Common Sense Services, LLC
   Key Principles towards Flow

• Reduce or Remove sources of Variation

• Create Standardized Work

• Implement Small Lots

• Increase Frequency



                Common Sense Services, LLC
Common Sense Services, LLC

								
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