Lean General Concepts

Mayo 2011

Ernesto A. Salas Velo

 Dinosuars were the largets animals to
ever live on the Earth…..

… why did they disappear?

 What’s your theory???

The Killer Comet?

A Volcanic Eruption?

Another Ice Age?

A New Virus Strain?

 All of these are good guesses, but
there is one common, underlying
thread……..

….they had a small brain.

 Life was good for the dinosaurs…..

They had plenty of resources (food)

They had a comfortable routine
Eat
Sleep
Repeat
….but when a new force entered their
environment, they were unable to cope with
the change.
 Don’t become the next “dinosaur”
Good times are the best time for kaizen
Exercise your brain
Establish a resilient enterprise
During bad times, the unprepared are vulnerable
A strong company can absorb your market share
You can be left with “no food”
The balance of this presentation will focus on the concept of
Total Flow
Lean Principles
Management
Kaizen
KANBAN
Logical Approach

Enfoque Inicial
de Materiales
Logical Approach
 Manufacturing Connections
i ti o n OS: Supermarket
Co nd
Pre-
Objective
Defined area for a collection of unique and specific material
storage locations within the plant utilizing proper visual
management techniques (controls) to facilitate material and
information flow. A controlled environment for target inventory
levels to assist in implementing and deploying proper
handling conditions (standardized work elements creating
self-service conditions) while providing:
• High manpower utilization
• High machine and floor space utilization
• Proper stock rotation
– First-in-First-Out (FIFO)
Supporting pull management along with providing proper
monitoring and feedback compliance performance (normal
and abnormal conditions)
Designated area utilized to store raw material, work-in-
process and finished goods. An area to provide the
connection between supply-base ordering and internal
production scheduling
 OS Implementation Sequence
Manufacturing Plant

Plant
 Manufacturing Connections
c ti on
onn e OS: Delivery Routes
C
Objective
Defined process design within the facility
supporting the material and information flow of raw
material, work-in-process and finished goods. The
connection utilizing proper visual management
techniques (controls) and standardized work
elements while providing:
• High manpower utilization
• High equipment utilization
• Proper stock rotation
– First-in-First-Out (FIFO)
Supporting pull management , small lot and high
delivery frequency.
 OS Implementation Sequence
Manufacturing Plant

Plant
 Manufacturing Connections
c ti on
onn e OS: Dock Operations
C
Objective
Defined process design within the facility
supporting the material and information flow of
receipt of raw material and returnable
containers/dunnage along with the staging and
eventual shipping of finished goods. The
connection utilizing proper visual management
techniques (controls) and standardized work
elements while providing:
• High manpower utilization
• High equipment utilization
• High dock bay utilization
Documented Receiving and Shipping Windows
• To coordinate all activities and measure compliance to plan
Designed and balanced operator workload
 OS Implementation Sequence
Manufacturing Plant

Plant
Logical Steps
Logical Steps
 5 Lean Principles

Lean Principles Measurements & Tools Just Two Actions

Priority 1 1. Make right part, right - ABC analysis OS Confirmation:
time, right quantity - Sleeping time
- Clear connections OS Change
- Schedule adherence Push or Fuzzy
2. Short lead time - Lot cycle policy Kanban
- Small Lot to
Strict Pull or BTO
- Quick set ups
3. Built in quality - FTQ
- Quality gate (QVC gate)
Priority 2 Efficiency
4. High capacity utilization - Equipment/tools
- ATT/ TT….95% Improvements:

Standardized Work
Implementation
5. High resource utilization ∑ CT, SOS, WCT
∑ ET Implement 100%
Management