Professional Documents
Culture Documents
Full Chapter Suggesting Solutions Brainstorming Creative Ideas To Maximize Productivity 1St Edition Protzman PDF
Full Chapter Suggesting Solutions Brainstorming Creative Ideas To Maximize Productivity 1St Edition Protzman PDF
Full Chapter Suggesting Solutions Brainstorming Creative Ideas To Maximize Productivity 1St Edition Protzman PDF
https://textbookfull.com/product/creative-solutions-to-global-
business-negotiations-second-edition-cellich/
https://textbookfull.com/product/creative-solutions-to-global-
business-negotiations-3rd-edition-claude-cellich/
https://textbookfull.com/product/creative-safety-solutions-
second-edition-schneid/
https://textbookfull.com/product/digital-design-in-action-
creative-solutions-for-designers-1st-edition-ciolek/
Brainstorming Questions in Toxicology 1st Edition P. K.
Gupta (Author)
https://textbookfull.com/product/brainstorming-questions-in-
toxicology-1st-edition-p-k-gupta-author/
https://textbookfull.com/product/how-to-prepare-the-egg-and-
embryo-to-maximize-ivf-success-gabor-kovacs/
https://textbookfull.com/product/healing-herbs-how-to-grow-store-
and-maximize-their-medicinal-power-1st-edition-alyssa-holmes/
https://textbookfull.com/product/baseline-confronting-reality-
and-planning-the-path-for-success-1st-edition-protzman/
https://textbookfull.com/product/sorry-spock-emotions-drives-
business-proving-the-value-of-creative-ideas-with-science-adam-w-
morgan/
Suggesting Solutions
Lean is about building and improving stable and predictable systems and processes to deliver to custom-
ers high-quality products/services on time by engaging everyone in the organization. Combined with
this, organizations need to create an environment of respect for people and continuous learning. It’s all
about people. People create the product or service, drive innovation, and create systems and processes,
and with leadership buy-in and accountability to ensure sustainment with this philosophy, employees
will be committed to the organization as they learn and grow personally and professionally.
Lean is a term that describes a way of thinking about and managing companies as an enterprise. Becom-
ing Lean requires the following: the continual pursuit to identify and eliminate waste; the establishment
of efficient flow of both information and process; and an unwavering top-level commitment. The con-
cept of continuous improvement applies to any process in any industry.
Based on the contents of The Lean Practitioners Field Book, the purpose of this series is to show, in de-
tail, how any process can be improved utilizing a combination of tasks and people tools and introduces
the BASICS Lean® concept. The books are designed for all levels of Lean practitioners and introduces
proven tools for analysis and implementation that go beyond the traditional point kaizen event. Each
book can be used as a stand-alone volume or used in combination with other titles based on specific
needs.
Each book is chock-full of case studies and stories from the authors’ own experiences in training orga-
nizations that have started or are continuing their Lean journey of continuous improvement. Contents
include valuable lessons learned and each chapter concludes with questions pertaining to the focus of the
chapter. Numerous photographs enrich and illustrate specific tools used in Lean methodology.
Suggesting Solutions: Brainstorming Creative Ideas to Maximize Productivity explores the process
block diagram tool, how to do a Lean layout and Lean master layout and how to create standard work
and visual management systems. The goal of this book is to introduce the balance of the tools and how
to proceed once the analysis is completed. There are many pieces to a Lean implementation and all of
them are interconnected. This book walks through the relationships and how the data presented can be
leveraged to prepare for the implementation. It also provides suggest solutions for improvements and
making recommendations to management to secure their buy-in and approval.
and by Routledge
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
The right of Charles Protzman, Fred Whiton and Joyce Kerpchar to be identified as authors of this work has been asserted by
them in accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical,
or other means, now known or h ereafter invented, including photocopying and recording, or i n any information storage or
retrieval system, without permission in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification
and explanation without intent to infringe.
DOI: 10.4324/9781003185796
Typeset in Garamond
by KnowledgeWorks Global Ltd.
Acknowledgments...................................................................................................................xvii
About the Authors....................................................................................................................xix
Introduction...........................................................................................................................xxiii
vii
viii ◾ Contents
Guideline 8: Co-Locate Executives and Office Staff on or Near the Floor or Areas
with Their Products.......................................................................................................25
Guideline 9: Don’t Plan Rework Inside a Cell...............................................................25
Guideline 10: Develop a Master Layout Early in the Project.........................................25
Guideline 11: Layout Approval..................................................................................... 26
Guideline 12: Housekeeping........................................................................................ 26
How Do We Know When the Layout Is Right?................................................................ 26
Struggling to Get the Layout Right?............................................................................ 27
Ten-Step Master Layout Process....................................................................................... 30
Layout Review.................................................................................................................. 30
Future Requirements Analysis.......................................................................................31
Point-to-Point Diagram.................................................................................................31
Architects versus Lean Hospitals....................................................................................... 34
Ideal Layout................................................................................................................. 34
Assumptions and Options and Barriers.........................................................................35
Block Layout Draft...................................................................................................... 37
Detail Layout............................................................................................................... 38
Phased Implementation Plan........................................................................................ 39
ROI Analysis................................................................................................................ 39
Typical Approach to a Master Layout............................................................................... 39
Lean and Architects..................................................................................................... 43
Hospital Results—Laboratory...................................................................................... 43
Master Layout Results.................................................................................................. 43
Workstation Design..................................................................................................... 44
Materials Should Be Fed from the Back of the Workstation..........................................47
Batching Fixtures and Workstations Must Be Modified or Removed............................47
Plan for Every Tool....................................................................................................... 49
Tooling Placement........................................................................................................ 49
Tooling Notes...............................................................................................................51
Personal Tools versus Company-Owned Tools..............................................................52
Toolboxes......................................................................................................................52
Tools for Machine Setups............................................................................................. 54
Problem with Shadowed Tools..................................................................................... 54
Sitting versus Standing and Walking Operations......................................................... 54
Implementing Workstation Design.............................................................................. 56
Point-to-Point Diagram After....................................................................................... 56
Station Balancing and Load Balancing............................................................................. 58
Proper Sizing of the Quantity of Supplies Needed........................................................59
Fit Up................................................................................................................................59
Centralized versus Decentralized................................................................................. 60
Bringing Up the Line....................................................................................................61
Stall Tactic....................................................................................................................61
Free Beer Tomorrow......................................................................................................61
Waiting to Solve Every Possible Situation..................................................................... 62
Training....................................................................................................................... 62
Production is Most Important...................................................................................... 62
Parallel Implementation............................................................................................... 63
Start with the Team Leader or Group Leader/Supervisor............................................. 63
Contents ◾ ix
MRP/ERP Systems..........................................................................................................167
Class A MRP Systems......................................................................................................168
Electronic Kanban Systems..............................................................................................169
Min/Max: Replenishment Pull....................................................................................169
Internet-Based Systems: Nocturne...............................................................................169
Scrap, Excess, and Obsolete.............................................................................................169
Expensing versus Capitalizing Parts.................................................................................170
Robbing Parts from the Lean Line..............................................................................171
Recycling Containers.......................................................................................................171
Chapter Questions...........................................................................................................172
Notes ..............................................................................................................................172
Additional Readings........................................................................................................173
DFA Results................................................................................................................233
Beyond Time and Dollars: The Hidden Benefits.........................................................233
Reviewing an Assembly Using DFMA....................................................................... 236
DFA Results............................................................................................................... 238
How to Apply Lean Principles to the Engineering
Process Itself................................................................................................................... 240
Lean Implementation Degree of Difficulty Scale........................................................ 240
Resistance to Change...................................................................................................... 240
Boeing Utilizing Innovation Teams to Increase 737
Production................................................................................................................. 242
Where to Start: Overall Engineering Effectiveness Scale
for a Project.................................................................................................................... 242
Low-Hanging Fruit......................................................................................................... 243
Meetings.................................................................................................................... 243
Planned Downtime.................................................................................................... 243
Unplanned Downtime............................................................................................... 244
Phone Calls................................................................................................................ 244
Value-Added Criteria for Engineer (Must Meet All Three)......................................... 244
Searching—3 Seconds Rule....................................................................................... 244
How to Start Leaning the Engineering Design Process:
A Transactional Process.................................................................................................. 244
What Is the Design Process?....................................................................................... 244
Seven Wastes of Design...............................................................................................245
Other Engineering Wastes..........................................................................................245
Batching versus Sequential Engineering Design Processes.......................................... 246
What We Find in the Engineering Process..................................................................247
Baselining the Process: Study the Current Design Lead Time.....................................247
Value Stream Map the Process................................................................................... 248
Conduct a PFA on the Process and Draw a Point-to-Point Diagram.......................... 248
Ten Rules for Improving the Design Process.................................................................. 248
Importance of Design and +QDIP Delivery Lead Times........................................... 254
Tool Boards Exercise—Which Tools Don’t Belong?........................................................255
How Many Tools Does It Take to Put Together a Unit?..............................................256
Change and Engineers.....................................................................................................256
Change and Engineers: Factory Work Is beneath Them..............................................257
Change and Toyota Engineers.........................................................................................259
Engineering Software Development.................................................................................259
Menlo Innovations History and Context.........................................................................261
The Tangible Elements of the Menlo Way.................................................................. 262
Maintaining Energy................................................................................................... 262
Summary of Engineering Considerations....................................................................... 263
Test Lean Suggestions................................................................................................ 263
Production—Preparation—Process (3Ps)................................................................... 263
Product Design/Product Flow.................................................................................... 263
Materials.................................................................................................................... 264
Target Floor Cell for New Product............................................................................. 264
TPM...........................................................................................................................265
Contents ◾ xv
Chapter Questions...........................................................................................................265
Discussion Questions..................................................................................................265
Exercise...................................................................................................................... 266
Notes.............................................................................................................................. 266
Additional Readings........................................................................................................267
Appendix A - Study Guide..................................................................................................... 269
Appendix B - Acronyms......................................................................................................... 277
Appendix C - Glossary........................................................................................................... 283
Index....................................................................................................................................... 305
Acknowledgments
There are many individuals who have contributed to this book, both directly and indirectly, and
many others over the years, too many to list here, who have shared their knowledge and experi-
ences with us. We would like to thank all of those who have worked with us on Lean teams in
the past and the senior leadership whose support made them successful. This book would not
have been possible without your hard work, perseverance, and courage during our Lean journey
together. We hope you see this book as the culmination of our respect and appreciation. We apolo-
gize if we have overlooked anyone in the following acknowledgments. We would like to thank the
following for their contributions to coauthor or contribute to the chapters in this book:
◾ Special thanks to our Productivity Press editor, Kris Mednansky, who has been ter-
rific at guiding us through our writing project. Kris has been a great source of encour-
agement and kept us on track as we worked through what became an ever-expanding
six-year project.
◾ Special thanks to all our clients. Without you, this book would not have been possible.
◾ Russ Scaffede for his insight into the Toyota system and for his valuable contributions
through numerous e-mail correspondence and edits with various parts of the book.
◾ Joel Barker for his permission in referencing the paradigm material so important and inte-
gral to Lean implementations and change management.
◾ Many thanks to the “Hats” team (you know who you are).
◾ I would like to acknowledge Mark Jamrog of SMC Group. Mark was my first Sensei and
introduced me to this Kaikaku-style Lean System Implementation approach based on the
Ohno and Shingo teachings.
◾ Various chapter contributions by Joe and Ed Markiewicz of Ancon Gear.
For the complete list of acknowledgments, testimonials, dedication, etc. please see The Lean
Practitioner’s Field Book. The purpose of this series was to break down and enhance the original
Lean Practitioner’s Field Book into six books that are aligned with the BASICS® model.
Authors’ Note: Every attempt was made to source materials back to the original authors. In the
event we missed someone, please feel free to let us know so we may correct it in any future edition.
Many of the spreadsheets depicted were originally hand drawn by Mark Jamrog, SMC Group,
put into Excel by Dave O’Koren and Charlie Protzman, and since modified significantly. Most of
the base formatting for these spreadsheets can be found in the Shingo, Ohno, Monden, or other
industrial engineering handbooks.
xvii
xix
xx ◾ About the Authors
executives had taken the course by 1956. The course continued until 1993. Many of the lessons
we taught the Japanese in 1948 are now being taught to Americans as “Lean principles.” The
Lean principles had their roots in the United States and date back to the early 1700s and later to
Taylor, Gilbreth, and Henry Ford. The principles were refined by Taiichi Ohno and expanded
by Dr. Shigeo Shingo. Modern-day champions were Norman Bodek (the Grandfather of Lean),
Jim Womack, and Dan Jones.
Charles participated in numerous benchmarking and site visits, including a two-week trip to
Japan in June 1996 and 2017. He is a master facilitator and trainer in TQM, total quality speed,
facilitation, career development, change management, benchmarking, leadership, systems think-
ing, high-performance work teams, team building, Myers-Briggs® Styles, Lean thinking, and sup-
ply chain management. He also participated in Baldrige Examiner and Six Sigma management
courses. He was an assistant program manager during “Desert Storm” for the Patriot missile-to-
missile fuse development and production program. Charles is a past member of SME, AME, IIE,
IEEE, APT, and the International Performance Alliance Group (IPAG), an international team of
expert Lean Practitioners (http://www.ipag-consulting.com).
This book is part of the BASICS Lean® Implementation Series and was adapted from The Lean
Practitioner’s Field Book: Proven, Practical, Profitable and Powerful Techniques for Making Lean
Really Work. I n B ook 3 , w e s tart w ith d iscussing t he S uggest S olutions s tep o f t he B ASICS
Lean® Implementation Model. These steps include how to create standard work and the differences
between standard work and work instructions, implementing Lean and Strategic Materials solu-
tions, the importance of using Creativity before Capital, and the role Engineering Plays in Lean
Solutions.
The books in this BASICS Lean® Implementation Series take the reader on a journey begin-
ning with an overview of Lean principles, culminating with employees developing professionally
through the BASICS Lean® Leadership Development Path. Each book has something for everyone
from the novice to the seasoned Lean practitioner. A refresher for some at times, it provides soul-
searching and thought-provoking questions with examples that will stimulate learning opportuni-
ties. Many of us take advantage of these learning opportunities daily. We, the authors, as Lean
practitioners, are students still thirsting for knowledge and experiences to assist organizations in
their transformations.
This series is designed to be a guide and resource to help you with the ongoing struggle to improve
manufacturing, government, and service industries throughout the world. This series embodies true
stories, results, and lessons, which we and others have learned during our Lean journeys. The concept
of continuous improvement applies to any process in any industry. The purpose of this series is to
show, in detail, how any process can be improved utilizing a combination of tasks and people tools.
We will introduce proven tools for analysis and implementation that go far beyond the traditional
point kaizen event training. Several CEOs have shared with us; had they not implemented Lean,
they would not have survived the Recession in 2008 and subsequent downturns.
Many companies prefer not to use their names in this book as they consider Lean a strategic
competitive a dvantage i n t heir i ndustry, a nd s ome of t hese c ompanies h ave now moved i nto a
leadership position in their respective markets; thus, we may refer to them as Company X through-
out the series. We explain to companies that Lean is a 5-year commitment that never ends. About
80–90% of the companies with which we have worked have sustained their Lean journeys based
on implementing our BASICS® Lean approach that we will share with you in this book.
The BASICS Lean® Implementation Series discusses the principles and tools in detail as well as
the components of the House of Lean. It is a “how to” book that presents an integrated, structured
approach identified by the acronym BASICS®, which when combined with an effective business
strategy c an h elp en sure t he s uccessful t ransformation o f a n o rganization. The L ean c oncepts
described in each book are supported by a plethora of examples drawn from the personal experi-
ences of its many well-known and respected contributors, which range from very small machine
shops to Fortune 50 companies.
xxiii
xxiv ◾ Introduction
The BASICS Lean® Implementation Series has both practical applications and applications in
academia. It can be used for motivating students to learn many of the Lean concepts and at the
end of each chapter there are thought-provoking questions for the reader to help digest the mate-
rial. The investment in people in terms of training, engagement, empowerment, and personal and
professional growth is the key to sustaining Lean and an organization’s success. For more on this
topic, please s ee our b ook L ean L eadership B ASICS®. L ean practitioners follow a n atural flow,
building continually on previous information and experiences. There is a bit of the Lean practitio-
ner in all of us. Hopefully, as you read these books to pursue additional knowledge, as a refresher
or for reference, or for academia, it can help expand your knowledge, skills, and abilities on your
never-ending Lean journey.
Chapter 1
DOI: 10.4324/9781003185796-1 1
2 ◾ Suggesting Solutions
Figure 1.2 Waste elimination funnel—as you reduce waste, you increase velocity or through-
put time.
The BASICS® Model: Suggest Solutions ◾ 3
Figure 1.3 (a) Linside storage right and VMI supermarket to the left of the aisle and (b) Tristate
Labeling supplied for VMI materials.
◾◾ Implement line side point of use (POU) materials and material warehouses next to or near
the line.
◾◾ Move toward Kanban or set parts/pallet systems (SPS) systems with vendor-managed inven-
tory (VMI) replenishment systems (see Figure 1.3).
◾◾ Flatten bills of materials. Eliminate all kitting and stocking of subassemblies from the
stockroom.
◾◾ Eliminate traditional stockrooms over time.
◾◾ Create and develop adherence to standard work.
◾◾ Implement visual controls.
◾◾ Implement accountability and discipline throughout the organization.
◾◾ Create a learning organization by developing your people.
◾◾ Remove silo-based management and move to a cross-functional organization.
◾◾ Create accountability-based systems at all organizational levels to ensure success.
Once the initial analysis is completed, we construct a block diagram. The block diagram takes
the output from the (to be) PFA and (to be) WFA and combines them into one flow. We develop
this tool with the operator and supervisors present. The block diagram sets the stage for the work-
station design and layout.
different alternatives for building the product. Once all the steps are on the board, start to ask
the following questions:
◾◾ Do we have all the models in the flow? Can we change the flow to streamline it even more?
◾◾ Does it really flow?
◾◾ Do note where there are subassemblies (or pre-assembly operations). Are the subassemblies
in the right order? Can they be incorporated into the line?
◾◾ Is this really the right order for each step from the part or product’s viewpoint?
◾◾ Do we have to carry a subassembly with us? Is there a way to build it into the product
directly? Can we deliver it without carrying it (i.e., gravity conveyor)?
◾◾ Is there a way we could rearrange and/or combine steps that make more sense or make it
easier to assemble? Could we build it from the ground up starting with a subassembly or do
we have subassemblies that have to be built in parallel? (This will mean that one of the subas-
semblies may have to be carried along while the other subassembly is produced.)
◾◾ Would changing the order of steps help in mistake proofing any steps?
◾◾ Would simplifying (removing complexity) help in mistake proofing?
For a mixed model line, we need to review each model and add any unique steps (in a different
color) where they fit in the block diagram for each model as necessary. Many times, it is surpris-
ing that very few, if any, steps must be added (see Figure 1.5). As one looks at mixed model lines,
check routings to see where any variance initially occurs. You may be surprised how far along the
value stream this occurs.
Another random document with
no related content on Scribd:
Vanha rouva asettui tavalliselle paikalleen ikkunan luona olevan
ompelupöydän ääreen; mutta tällä kertaa hän ei ottanut esille
tavanmukaista reikäompelustaan tai virkkuutaan, vaan kääri auki
kirjeen. Hänellä oli samalla kummallisen juhlallinen ilme. Hannan
sydäntä kouristi; hän aavisti jotain erikoista tapahtuneen.
»Rakas lapsi, ota tuo palli ja istuudu tänne ja kuuntele mitä minulla
on sinulle sanottavaa. Kuten tiedät, olen minä sinun suhteesi äidin
asemassa. Minun täytyy valvoa etuasi ja suojella sinua. Pelkään
sinun olevan… liian kiemailevan… Sinun ikäisenäsi olin tosin
minäkin kiemaileva, mutta ainoastaan sellaisille ihmisille, joille äitini
luvalla sain kiemailla. Olen vakuutettu, että sinulla ensi talvena on
tilaisuus keskiviikkokutsuissani tehdä sopivia valloituksia. Siellä on
esimerkiksi majuri, paroni Schimmerer, joka on leskimies ja omistaa
kolmikerroksisen talon jossain Wienin esikaupungissa…»
»Ja miksi en! Äiti sanoi aina, että minusta on tuleva kreivitär tai
miljoonain omistaja…»
Hanna oli tuskin jäänyt yksin, kun jo suli kyyneliin. Nyt hän vasta
selvästi tunsi rakastavansa nuorta tiedemiestä. Ja tämä… tämä oli
pyytänyt häntä vaimokseen; varmaankin riippui hänen elämänsä
vastauksesta… ja kummitäti aikoi musertaa hänen sydämensä
rukkasilla. Ei, tapahtukoon mitä hyvänsä, hän vastaa myöntyvästi.
»Sisään!»
»Tulevaisuuteni.»
»Vastaus on myöntävä.»
Hanna huokasi.
»Ei, ei… pukujen takia en epäile… mutta jos Ewald ei ole mukana,
on kai sopimatonta…»
»Oh, miten ikävä ilta!» hän huokaa. »Miten olet nyt huvitellut
lapsi?»
»Kuninkaallisesti!»