Production Philisophy

What is LEAN?

The core idea is to maximize customer value while minimizing waste.

Lean means creating more value for customers with fewer resources.

flow time

product starts product ready for

processing time
process next process

flow time = processing time + waiting time

Tools --> implement + suport

Involve Continuus Remove = faster, reliable, better

Employees Improvements Waste quality, improve price

Culture & Change KPIs JIT [Just In Time]

[Key Performance Indicators] #produced = #required
Team oriented Goals we must reach
(must be reachable) before - Inventory
Problem solving after - happy customers
Vision
Job improvements Goals that are never
reached

Classic LEAN

product A product A
each stop seperated no buffer inventory
Inventory order deliver
-->
<--

vs
breakdowns product B product B problems become visible
= less effective
Inventory order deliver
-->
<--

responsibility product C product C responsibility

“YOUR problem” “OUR problem”

sacrifices 100%
7 Types of Waste to combat: capacity utilization
[the amount of available ca-
T Transport pacity that is being used to
I Inventory supply current demand]
M Motion
low capacity utilization
W Waiting -> produce less
O Overprocessing
O Overproduction max capacity utilization
D Defects -> inventory
Tools to combat waste

Value Chain End-to-End-process to create Value

--> for whom?

Processes
1 what should be mapped cycle time
one piece done til next one done
change over time
2 draw on paper --> current situation [wechsel des produkts]
screens are barriers staffing
Inventory
3 problems + solutions --> future situation
finished goods
buffers
raw materials
4 implementation
how do you want to do the change Information
forecast
planning
orders

5S
Housekeeping
Method No Waste
" KAN B AN "
Uncertainty
japanese: sign, billboard
waiting time
use cards as visual management system
limits WIP tasks
searching for
instant overview
infos / tools

Sort
Shine (clean environment)
Standards
Systemize
Sustain (keep it that way)

SMED
Single Minute Exchange of Dies

a technique to reduce overall downtime of a machine.

also including the supply with materials and setup/calibra-

tion of the new dies.

aim to reduce the overall changing process to a single digit

time (less than 10 minutes)
 Layout

improve flow / flexibility " Poka - Yoke "

short LEAD time Japanese term that means "mistake-proofing"
[Durchlaufzeit]
U-Shape idiot-proofing components and processes
(physical placement) --> improves quality
FIFO
(first in first out)
TAKT
(adapt production to Boards communication 5 min daily meet-
demand) ings
goals = common follow-ups
(makes it easier) (feedback !!! )