1. WASTE REDUCTION AND PRODUCTIVITY IMPROVEMENT
SAMPLE
DAY 1

2. You are not paid to work hard
You are not paid to work hard. In fact, you are not paid for effort at all. You are paid for results. It's not what you do; it's what you get done.“ ----Larry Winget : Personal success and business author and speaker
SAMPLE

3. EVERY BUSINESS HAS TWO SOURCES OF CASH FLOW
Cash is the lifeblood of your business. To boost profits, you will want to earn more or lose less. Every business has two sources of cash flow:
External customers give you money for your products and services.
Internal processes that leak cash like a rusty bucket.
—25% to 40% of your expenses.
SAMPLE

4. EVERY BUSINESS PROCESS HAS THREE BIG LEAKS
Big Leak #3—Variation
SAMPLE
Big Leak #1—Delays: The delays between the steps in your process cost you time and money that dampen your productivity and profitability.
Big Leak #2—Defects: The defects, mistakes and errors that have to be fixed or scrapped. Fixing mistakes that shouldn’t have been made in the first place consumes time and money that could be better spent serving
customers and boosting the bottom line.
Big Leak #3—Variation: The small to large differences from piece-to-piece, day-to-day, month-to-month of your products and services.

5. Every Business Has Two Improvement Focuses1)
(2)
SAMPLE
Big Leak #1—Delays: The delays between the steps in your process cost you time and money that dampen your productivity and profitability.
Big Leak #2—Defects: The defects, mistakes and errors that have to be fixed or scrapped. Fixing mistakes that shouldn’t have been made in the first place consumes time and money that could be better spent serving
customers and boosting the bottom line.
Big Leak #3—Variation: The small to large differences from piece-to-piece, day-to-day, month-to-month of your products and services.

6. LEAN Thinking
Identify waste ( as defined by the customer ) and…..
Determine appropriate and effective ways to remove waste from the system.
SAMPLE 6

7. Types of Work – Identifying Waste
Value Adding (VA):
SAMPLE
Incidental Work (NVA),
Waste 7

8. SAMPLE Waste Elimination Value Add Waste Lean Six Sigma
Traditional Focus
Work Longer-Harder-Faster
Add People or Equipment
SAMPLE
Lean Six Sigma
Improve the Value Stream to Eliminate Waste
Value
Add
Waste
LEAD TIME 8

9. To produce sooner, faster or in greater quantities
The 7 Wastes
Overproduction
Waiting
Inventory
Transportation
Motion
Excessive Processing
Defects 1 6 7 5 4 3 2
To produce sooner, faster or in greater quantities
than customer demand.
Raw material,
work in progress
or finished goods
which is not having
value added to it.
People or parts
that wait for
a work cycle to
be completed.
Unnecessary movement
of people, parts or
machines within
a process.
Unnecessary movement of people
or parts between processes.
Non right
first time.
Repetition
or correction
of a process.
Processing
beyond
the standard
required by the
customer.
is the Japanese word for WASTE.
MUDA
Seek it out and get rid!
An 8th waste
is the wasted
potential
of people
SAMPLE 9

10. TOOLS FOR WASTE REDUCTION AND PRODUCTIVITY IMPROVEMENT
SAMPLE

11. Setup Reduction (SMED)
SAMPLE

12. Poka Yoke
SAMPLE

13. One-Piece Flow
SAMPLE

14. Total Productive Maintenance (TPM)
SAMPLE

15. Pull System
SAMPLE