Lean production implementation roadmap by lpx20272

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									                                      A GUIDE FOR THE LEAN JOURNEY
                             Lean production implementation roadmap

                                          Phase                                Phase                               Phase                               Phase                            Phase


                                          PLAN                                 APPLY                           DEPLOY                              INTEGRATE                            EXCEL
                                      1 – 6 months                       3 – 6 months                      2 – 12 months                          2 – 6 months                  Forever and always
                                Perform
                                                                      Initial application             Additional teams form                            Teams                            Teams
                                                   Corporate
                               assessment          diagnosis           area teams form                      and norm                                  perform                         transform

                                                                    Prepare and       Workplace           Deploy phase 2 activites             Deploy phase 3 activites          Deploy phase 4 activites
                                                                       focus            scan                throughout plant                     throughout plant                  throughout plant
                                                   Decision to
                                                   implement
                                                      lean                                                                                                                                       New ideas
                              Define goals,                                                           Improve implementation plan               Deploy lean enterprise         Break your
                                                   production                                                                                                                                    for future
                               objectives,                                             Develop                                                      in value chain             paradigms
                                                                       Apply                                                                                                                   improvement
                              measures, and                                             criteria,
                                                      Lean              5S           prepare team
                               milestones                                                                                                                      CIM and FMS
                                                   production                         assess, etc.    Repeat application in other areas                                                             FMS
                                                     policy
                                                                                                                                            Educate and                       Invest in R&D
                                                   statement                                                                                                     Internal                          CIMS
                                                                    Standardize                                             Multi            involve all                         of new
                                                                                       Standard                                                                integration    methods and
                                                                     work and                                              machine           employees
                                                                                      work combo                                                                               technology        Operator
                                 Establish                           inventory                           Apply             handling
                                                     Team                               sheets                                                                                                  automation
                                  a lean                               buffers                          advanced
                                                    charters                                                              Additional                                                             specialists
                               organization                                                             one-piece
                                                                                                          flow              TPM                     Analyze results
                                                                                     Standardized                                                                                                  Trade
                                                                     One-piece                                            Cycle time
                                                  Target means                       work direction                                                                                               journals
                                                                       flow                                              management                                           Publish your
                                 Research            analysis                           manual                                                 Apply             Link to
                                  current                                                                                                                                       results         Productivity
                                                                                                                                             concurrent          process
                                conditions            Lean        Implement                                                                 engineering        engineering                       books and
                                                   production        area                             Implement autonomation (jidoka)                                                           newsletters
                                                   assessment       specific
                                                                   methods
                                                                                                                                                                                  CELEBRATE SUCCESS!
                                                                                                                                                    Analyze results
                               PO        Deploy     Visual          Apply quick      Standardized     Implement production smoothing
                             matrix      policy   management        changeover       CO procedures
                              and         and        plan
                             master      master                                                                                            Initiate supplier
                                                                                                                                                                 Link to
                              plan        plan     Training and                                               Analyze results               development
                                                                         Apply autonomous                                                                      supply chain
                                                    education                                                                                  program
                                                       plan                maintenance

                             Catchball                                                                                      Address
                                                                                                         Apply a            system
                                                                                                         kanban           integration               Analyze results
                                                                        Apply visual controls            system              issues,
                                                   Awareness                                                             schedules, etc.
                              Communicate          education
                                                                                                                                               Apply             Link to
                                 policy                               Apply mistake proofing                                                                    customers
                                                     Formal                                                   Analyze results                   QFD
                                                     launch
                                                                                        Lessons
                                                                      Analyze         learned and                                                   Analyze results
SOURCE: PRODUCTIVITY, INC.




                                                                      results                              Interface with MRPII
                                                                                         targets
                                                                                       refocused

                                                                                        Inspired                                                  Study results and
                                                                                                              Analyze results                      revise strategy
                                                                      Reapply            safety
                                                                        5S             condition
                                                                                       program

								
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