Lean Lesson 3 - 2023 - Materials

a.
Uniform plant loading/ heijunka
• Heijunka is a system of production-

leveling that produces the right product
mix as demanded by the customer by
making optimal utilization of the available
capacity
• There is one heijunka by product type

and one by production quantity
https://www.slideshare.net/nehajags/principle-4-heijunka?from_action=save
Copyright ©2017 McGraw-Hill Education. All rights reserved. 1
Example Heijunka by production quantity
https://ocw.mit.edu/courses/engineering-systems-division/esd-60-lean-six-sigma-processes-summer-
Copyright ©2017 McGraw-Hill Education. All rights reserved.
2004/lecture-notes/9_3product_level.pdf 3
WHAT HEIJUNKA DOES
• Stabilizes production volume and variety by
consolidating the total number of
customer orders
• Spreads out the production during the day
• Ensures internal production is balanced
• Established capacity is not over or under-
utilized
https://www.slideshare.net/nehajags/principle-4-heijunka?from_action=save
a. Uniform plant loading/ hejunka

It’s not possible to talk about Heijunka without talking about
Takt time
• In fact, the Heijunka concept is closely connected with
Takt time concept
.
• It is derived from the German word, Taktzeit, which is
often referred to as the heartbeat or drumbeat of
production in Lean Manufacturing.

https://emergeapp.net/traditional-businesses/takt-time-for-manufacturers/
https://efinancemanagement.com/financial-management/takt-time-vs-cycle-time
Heijunka
https://www.youtube.com/watch?v=VSr0VG7peCA
Only initial part…

b. Determination of number of Kanbans needed
Kanban Production Control Systems

A kanban is a card that indicates quantity of production
• As Kanban, cards or containers are used

• Kanban make up the pull system
Kanbans maintain the discipline of pull production

- A production kanban authorizes production
- A withdrawal kanban authorizes the movement of goods
Copyright ©2017 McGraw-Hill Education. All rights reserved. 14-11

Supermarket logic

https://www.youtube.com/watch?v=W8dKoRjFvTY

Withdrawal kanban/production kanban
• Withdrawal kanbans, also called "move cards" are

used to signal when a part is ready to move from one part of
the production process to another. The card is attached to a
prescribed number of parts, which are moved to the work area
that requires them. Once the parts are used, the card is
returned as a signal to send the same number of the same part
back.
• Production kanbans contain a comprehensive list of
everything the part requires in order to be completed. This
includes the materials required, the parts required and the
information included upon a withdrawal kanban. Essentially, a
production kanban orders the production system to get started
with production, as well as explaining what must be produced.
How to Calculate the number of
Kanban
• Number of Kanban = [ DD * LT * (1 + % SS) ]/ Q
DD =Daily Demand
LT = Lead Time (in Days)
SS = Safety Stock
Q = Quantity in a Container
http://www.leanlab.name/how-to-calculate-
the-number-of-kanban
Example
• Let us imagine a downstream process that uses 100
tapes/day (on average).
The lead time to obtain new tapes from the start to the
delivery is 5 days.
The Safety Stock in percentage is 20% (to compensate
demand variation or delays)
Every container is of 50 tapes.
N° of Kanban = 100 * 5 * 1,20 / 50 = 12 Kanban
http://www.leanlab.name/how-to-calculate-
the-number-of-kanban
c. Minimize setup times /SMED/QCO
• SMED/QCO (Singole Minute Exchange of Die or Quick
Changeover, was developed by Shigeo Shingo in Japan).
• DEFINITION:
• Quick changeover is the amount of time taken to
change a piece of equipment from producing the last good
piece of a production lot to the first good piece of the next
production lot.
• The impetus was to reduce costly inventories and improve

efficiency.
Copyright ©2017 McGraw-Hill Education. All rights reserved. 14-18

Exhibit 14.10
What is quick changeover?
A performance improvement activity that focuses on:
• Reducing the changeover time
• Reducing the cost and effort required to perform a

changeover
• Reaching the benefits that streamlined changeovers

provide to many related areas of the production system
www.lean.org/.../4-Quick%20Changeover%20-%20Updated%2...
A classic quick changeover example
https://www.youtube.com/watch?v=UlIGI3laGAo

TPM = total productive maintenance
• A company-wide team-based effort to build quality into

equipment and to improve overall equipment effectiveness
• all employees are involved

• it aims to eliminate all accidents, defects and breakdowns
• actions are performed while production goes on

• troubles for production are minimized
• keep in good condition

• repair, clean, lubricate
© Imants BVBA http://www.managementsupport.com

TPM and Traditional Maintenance
Reactive maintenance is wasteful and ineffective with

the following disadvantages:
• No warning of failure
• Possible safety risk
• Unscheduled downtime of machinery
• Production loss or delay
• Possible secondary damage
http://www.fkm.utm.my/~shari/download/tpm%20principles%20and%20concepts.ppt
Copyright ©2017 McGraw-Hill Education. All rights reserved. . 23
1. TPM definition (2)
combines the traditionally American practice of preventive

maintenance with Total Quality Control and Total Employee
Involvement, to create a
where operators develop ownership of their equipment, and

become full partners with Maintenance, Engineering and
Management to assure equipment operates properly
everyday.

2. Origins of TPM
• Dr. Deming introduced statistical analysis and used the
resulting data to control quality during manufacturing
(TQM)
• Some general concepts of TQM did not work well in the
maintenance environment
• The need to go further than preventive maintenance was
quickly recognized by those companies who were
committed to TQM
• Maintenance became an integral part of TQM in the
early 90’s
• sharing knowledge

3. TPM principles
• Improve existing planned maintenance systems
• Consider that the operator is the best condition monitor
• Provide training to upgrade operations and
maintenance skills
• Involve everyone and utilize cross-functional teamwork

b. 5s theory
https://www.youtube.com/watch?v=aMkXICM1-98

b. 5s theory
• 5S is a workplace organization methodology that uses a

list of five Japanese words which are seiri, seiton, seiso,
seiketsu and shitsuke.
It helps create and maintain the

efficiency and effectiveness of a
work area
A method of creating a clean and orderly workplace that

exposes waste and makes abnormalities immediately
visible
b. 5s theory
It is a way to create:
• Cleaner work areas
• More organization
• Safer working conditions
• Less wasted time
• Efficient work processes and practices
• More available space

b. 5s theory
• Sorting – separating the needed from the not-needed
• Simplifying o setting – a place for everything and

everything in its place, clean and ready to use
• Systematic Cleaning – cleaning for inspection
• Standardizing – developing common methods for

consistency
• Sustaining – holding the gains and improving

1st SEIRI – SORTING: example
Example: with visual sorting, a tactic which allows sorting
parts by colour
1. No need at all
2. Needed but not now
3. Needed but not here
4. Needed but not so much quantity

http://www.authorstream.com/Presentation/vikendra-410846-5s-training-entertainment-ppt-powerpoint/ 31
2nd SIMPLIFIYNG or SETTING: example

b. 5s theory: Systematic Cleaning

Example: visual indicator

b. 5s theory: Standardizing
• All work stations for a particular job should be

identical;
• All employees doing the same job should be
able to work in any station with the same
tools that are in the same location in every
station
• Everyone should know exactly what his or her
responsibilities are…
betterhttps://www.slideshare.net/AmarRaveendran/5-s-ppt
b. 5s theory: Sustaining
• Maintain and review standards

• Maintain focus on this new way and do not allow
a graduate decline back to the old ways;
• While thinking about the new way, also be
thinking about better ways
betterhttps://www.slideshare.net/AmarRaveendran/5-s-ppt
One piece flow
Make one, move one
Realisation of one piece at a time

without any waiting time between each
process.

https://www.youtube.com/watch?v=EWjRGOHnD2U

Batch vs One Piece Flow
https://www.slideshare.net/BillCW3/toyota-production-system-and-lean-tools

Lean Lesson 3 - 2023 - Materials

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lean Lesson 3 - 2023 - Materials

Uploaded by

Copyright:

Available Formats

a.

Uniform plant loading/ heijunka

• Heijunka is a system of production-

• There is one heijunka by product type

Copyright ©2017 McGraw-Hill Education. All rights reserved. 5

Copyright ©2017 McGraw-Hill Education. All rights reserved. 7

Only initial part…

Copyright ©2017 McGraw-Hill Education. All rights reserved. 10

Kanban Production Control Systems

• As Kanban, cards or containers are used

Kanbans maintain the discipline of pull production

Copyright ©2017 McGraw-Hill Education. All rights reserved. 14-11

Copyright ©2017 McGraw-Hill Education. All rights reserved. 12

Copyright ©2017 McGraw-Hill Education. All rights reserved. 13

• Withdrawal kanbans, also called "move cards" are

• Number of Kanban = [ DD * LT * (1 + % SS) ]/ Q

N° of Kanban = 100 * 5 * 1,20 / 50 = 12 Kanban

• The impetus was to reduce costly inventories and improve

Copyright ©2017 McGraw-Hill Education. All rights reserved. 14-18

• Reducing the changeover time

• Reducing the cost and effort required to perform a

• Reaching the benefits that streamlined changeovers

Copyright ©2017 McGraw-Hill Education. All rights reserved. 20

• A company-wide team-based effort to build quality into

• all employees are involved

• actions are performed while production goes on

• keep in good condition

© Imants BVBA http://www.managementsupport.com

Reactive maintenance is wasteful and ineffective with

1. TPM definition (2)

combines the traditionally American practice of preventive

where operators develop ownership of their equipment, and

© Imants BVBA http://www.managementsupport.com

© Imants BVBA http://www.managementsupport.com

© Imants BVBA http://www.managementsupport.com

Copyright ©2017 McGraw-Hill Education. All rights reserved. 27

• 5S is a workplace organization methodology that uses a

It helps create and maintain the

A method of creating a clean and orderly workplace that

Copyright ©2017 McGraw-Hill Education. All rights reserved. 29

• Sorting – separating the needed from the not-needed

• Simplifying o setting – a place for everything and

• Systematic Cleaning – cleaning for inspection

• Standardizing – developing common methods for

• Sustaining – holding the gains and improving

Copyright ©2017 McGraw-Hill Education. All rights reserved. 30

Copyright ©2017 McGraw-Hill Education. All rights reserved.

Copyright ©2017 McGraw-Hill Education. All rights reserved. 32

Copyright ©2017 McGraw-Hill Education. All rights reserved. 33

Copyright ©2017 McGraw-Hill Education. All rights reserved. 34

• All work stations for a particular job should be

• Maintain and review standards

Make one, move one

Realisation of one piece at a time

Copyright ©2017 McGraw-Hill Education. All rights reserved. 37

Copyright ©2017 McGraw-Hill Education. All rights reserved. 38

You might also like