5 How do we grow. How do we make the right product on time How do we grow ? How do we make the right product on time ? How do we lower our stock room inventory ? How do we maintain a good quality product ??
6 We could hire more people and buy more machines. This would cost us $$$$We could raise the price of our products.Currently our customers are asking us to REDUCE the price of our products!
7 BEFORE WE DO ANYTHING ELSE We need to become more efficient in our manufacturing. AND We need to find waste in our process and cut it out.
8 > Get all of the needed parts to Assembly at the right time. GOALS> Produce more product usingour current resources.> Lower our stock room inventory.> Accurately forecast exactly how long it takes tomake our products and ship them on time.> Get all of the needed parts to Assembly at the right time.
9 What isLEANA systematic approach to identifying and eliminating waste through continuous improvement in pursuit of perfection.Striving to do more with less, and do it consistently.Work Smarter Not Harder
10 THE LEAN FORMULA TEAMWORK OBSERVE IDEAS COMMUNICATION CULTURE FORM A TEAM OF PEOPLE,THE PEOPLE THAT ACTUALLYDO THE WORKOBSERVEANALYZE THE CURRENTSITUATIONIDEASTHE TEAM DEVELOPS IDEASON HOW TO ELIMINATE WASTECOMMUNICATIONMAKE SURE EVERYONE KNOWSTHE GOALS, THE CHANGESBEING MADE, THE SUCCESSES,AND THE FAILURESCULTURECREATE A CONTINOUSIMPROVEMENT CULTURE.ALWAYS CONSIDER NEW IDEAS
11 8 Forms of Waste Types of Waste DEFECTS WAITING EXCESS MOTION PROCESSINGEXCESSMOTIONINVENTORYTRANSPORTATIONOVER-PRODUCTIONRepair orRework.Any wasted motionto pick up parts orstack parts. Alsowasted walking.Transporting parts, orfinished goods into orout of storage, orbetween processes.Producing morethan is neededbefore it is needed.Maintaining excessinventory of parts inprocess, orfinished goods.Doing more work thanis necessary.Any non-work timewaiting for tools,supplies, parts, etc..UNDERUTILIZEDPEOPLEWaiting for moreWork to do.
12 VALUE STREAM MAP We the operations. We We the operations. FINDING WASTE
14 SHINE, SET RULES, SUSTAIN. TOOLS5SSORT, SET IN ORDER,SHINE, SET RULES, SUSTAIN.STANDARDIZED WORKPRACTICESVISUAL CONTROLSTEAMSPLANTLAYOUTBATCHREDUCTIONQUICKCHANGEOVERPOINTOF USERSTORAGEQUALITY ATTHE SOURCEPRODUCTIONCELLSUPERMARKET FLOWPULL SYSTEMTOTAL PRODUCTIVEMAINTENANCE
15 KaizenKaizen EventThe definition of “Kaizen” has been Americanized to mean "Continual Improvement." A closer definition of the Japanese meaning of Kaizen is "to take apart and put back together in a better way."
16 COMMUNICATION ISOLATION SECRECY “Do you have any ideas ?” “Here’s what we are doing”“What problemsCan we solve ?”COMMUNICATION“Here’s whereWe are going”“How can we makethis better ?”