Professional Documents
Culture Documents
Lean Presentation
Lean Presentation
Lean Presentation
Introduction to Lean
Manufacturing as a part of
Industrial Engineering
Roadmap
Kanban
Waste
One Piece Flow
MRP
Inventory Management
Lean
Tools
Operations
Tools
5S
Standard
Work
Takt Time
Waiting Lines
Forecasting
5S
GILL
To Be
Ordered
Next Run
Maintenance
Log
&
Maintenance
Request Forms
In Process
Orderliness
Aplaceforeverythingandeverythingin
itsplace,cleanandreadyforuse
Maintenance
Replacement Part
Kanban
Addresses
Takt Time
fully integrated
manufacturing
system
Standardized Work
is only one part of a
Lean Philosophy
Customer First
No defect shall be passed to the customer
Continuous Improvement
There is always more to improve
Lean
Manufacturing
Lean Manufacturing
Lean Manufacturing
Customer
Order
Waste
Time
Product
Shipment
Business as Usual
Lean Manufacturing
is a manufacturing philosophy which shortens the time line
between the customer order and the product shipment by
eliminating waste.
Customer
Order
Waste
Product
Shipment
Time
Lean Manufacturing
Customer
Order
Waste
Time (Shorter)
Product
Shipment
Business as Usual
Product Leadtime
Transportation
Raw
Material
Packaging
Mixing
Staging
Inspection
Time
= Value
Added Time
= Non-Value
Added Time
(WASTE)
Set-up
Finished
Parts
Waiting
Raw Material
Production
Time
Time
Small Amount
of
Time
Eliminated
Time
Time
Small Amount
Time
of
Eliminated
Anything
Anything that
that adds
adds
Cost
Cost
to
to the
the product
product
without
without adding
adding
Value
Value
Waste
TIMWOOD - 7 Wastes.mp4
Shift Mindset
Waste
Inventory
Correction
Types
Of
Waste
OverProduction
Material
Movement
Waiting
Motion
Processing
Better Utilization
Work
Work
Waste
Waste
Work
Work
New
Paradigm
Waste
Waste
Work
Work
Work
Work
Waste
Waste
Waste
Waste
Three Components of
Standardized Work
Standardized
Work
Work
Sequence
Standard
In-Process
Stock
Takt
Time
Takt Time
The production rate, in seconds, to satisfy
System Development and
3/15/16
Monitoring
customer demand.
Example :
Takt Time
Cycle Time
Includes human and machine work, walking
time, and waiting time
Determine by observing the actual time to
process one part
Step C5
60
Step C4
50
40
Step A4
30
Step A3
20
Step A2
10
0
Step A1
Step B3
Step B2
Step B1
Step C3
Step C2
Step C1
Step
Step
Step
Step
Step
D5
D4
D3
D2
D1
Step
Step
Step
Step
E5
E4
E3
E2
Step E1
Operators
Step C5
60
40
Step A4
30
Step A3
20
Step A2
10
0
Step A1
Step C4
50
Step B3
Step B2
Step B1
Step C3
Step C2
Step C1
Step
Step
Step
Step
Step
D5
D4
D3
D2
D1
Step
Step
Step
Step
E5
E4
E3
E2
Step E1
Operators
Work Sequence
Work Sequence refers to the series of steps in a single process that is
fastest, most efficient, of acceptable quality, and safe. When the work
sequence is carefully followed, the cycle time will be constant, no steps
problems will be minimized.
Poor
Good
8
10
10
1
9
2
6
5
Step C5
60
Step C4
50
40
Step A4
30
Step A3
20
Step A2
10
0
Step A1
Step B3
Step B2
Step B1
Step C3
Step C2
Step C1
Step
Step
Step
Step
Step
D5
D4
D3
D2
D1
Step
Step
Step
Step
E5
E4
E3
E2
Step E1
Operators
50
40
50 sec
43 sec
30
48 sec
33 sec
20
15 sec
10
0
#1
#2
Cut &
Fold
Glue
Up
Tissue
Candy
Pen
60
Operators
60
40
Step A4
30
Step A3
20
Step A2
10
0
Step A1
Step B3
Step B2
Step B1
Step C3
Step C2
Step C1
Step
Step
Step
Step
Step
40
Step D5
Step E4
Step A4
Step C1
30
Step A3
20
Step A2
10
0
Step
Step
Step
Step
E5
E4
E3
E2
Step E1
Operators
60
50
D5
D4
D3
D2
D1
Step A1
Step D1
Step E1
Step B2
Step C3
Step D4
Step D3
Step D2
Step B1
Step C2
Step C5
Step B3
Step C4
Step C4
50
Step E5
Step E3
Step E2
Operators
Just-In-Time
Systems
System Development and
3/15/16
Monitoring
Mass Production
Storage
Storage
Receiving
Warehouse
Shipping
Warehouse
Assembly
Storage
Weld
Storage
Stamp
Rework
Storage
Material
Mass Production
Storage
Storage
Two
Big
Problems
Receiving
Assembly
Batch
Production
Shipping
Storage
Warehouse Poor Flow
Within processes
Value added time
Rework
=
Between processes
minutes
Large
Warehouse
Time in plant =
WEEKS
Weld
Storage
Stamp
Storage
Material
Batch &
Queue
Station A
Station C
Station B
HOW
HOW TO
TO MANUFACTURE
MANUFACTURE MOST
MOST
ECONOMALLY:
ECONOMALLY:
Just-In-Time
Just-In-Time
But This Assumes:
Equal Cycle Times
Physical Proximity of Processes
Highly Stable Processes
Little/No Changeover Time
Batch &
Queue
Station A
One Piece
Flow
Station C
Workcell
Station B
Just-In-Time
But This Assumes:
Equal Cycle Times
Physical Proximity of Processes
Highly Stable Processes
Little/No Changeover Time
Just-In-Time is
NOT a Zero
Inventory System.
Next Best =
Controlled Buffers + Pull
Kanban
Roadmap
Kata
Heijunka
Muda
TPS
Genchi Genbutsu
Kanban
Waste
One Piece Flow
MRP
Inventory Management
Lean
Tools
Operations
Tools
Kaizen
5S
Standard
Work
Takt Time
Waiting Lines
Forecasting
waste elimination
standardized work
poka yoke
5s visual workplace
just in time
continuous improvement
material management
work in process
POKA-YOKE
POKA-YOKE(continued)
POKA-YOKE(continued)
POKA-YOKE(continued)
20160302_165425.mp4
Thank
You!!!