2. Ten Steps to Lean Production

3. Steps to CIM 1.Re-engineer (revisit, replan) the manufacturing system Form U-cells to produce families of parts (clusters) Integrate production, inventories, Quality Control and machine tools

4. Steps to CIM 2.Setup reduction or elimination Identify elements that are “internal” and those that are “external” Improve methods (use a pit crew) Re-engineer to eliminate adjustments, mechanize, automate

5. Steps to CIM 3.Integrate quality control into the system Develop a systems approach Incorporate visual signals Work toward a “1 piece flow” Make 1, check 1, move 1 on

6. Steps to CIM 4.Integrate preventative maintenance into the system Reduce pressure on workers and the process (back off from 100%) Housekeeping – place for everything and everything in place Decrease system variability

7. Learning Loops in CIM

8. Steps to CIM 5.Level, balance, sequence and synchronize “Smooth” manufacturing Keep production “level” Make production “predictable” Incorporate “kanban” labelling Label

9. Steps to CIM 6.Production Control Integrate scheduling and control functions into the system Use MRP/ERP software Use the PC system to link cells together MRP = Manufacturing ERP = Enterprise DRP = Distribution CRP = Capacity BRP = Business

10. Schematic factory layout

11. Steps to CIM 7.Reduce work-in-process Excess inventories hide problems Reduce the inventory to expose problems Take immediate action to eliminate the problems

12. Steps to CIM 8.Integrate suppliers Work to reduce suppliers to a single source Develop trust & open communications Implement flexible procurement (supply purchasing) contracts Develop long-range forecasts

13. Steps to CIM 9.Automation Allow workers to control the process (trust in work force) Provide clear directions In-process controls and inspections Feedback loops

14. Steps to CIM 10. Computer-Integrated Manufacturing Enterprise-wide systems Remove functionality (independence) of departments Focus teams on product lines and customers

15. The REAL Goal is to become LEAN Waste eliminated Employees involved Customers satisfied Profits increased Company survival assured By printing and binding in the same factory, Butler and Tanner reduces the amount of transport required during the production process

16. Achieving CIM Toyota has been on a “journey” toward a waste free and coordinated operation for 45 years… and they know they are not there yet. The “steps” and “tools” help people understand the process of change, but there is much more that is required