Lean Manufacturing Series Lean Overview Lean Manufacturing Series

Contents Introduction Background and History Components and Implementation 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams Knowledge Check

Introduction What is Lean? Thinking Lean Lean focuses on eliminating waste in processes (i.e. the waste of work in progress and finished good inventories) Lean is not about eliminating people Lean is about expanding capacity by reducing costs and shortening cycle times Lean is about understanding what is important to the customer Thinking Lean Specify value from the perspective of the ultimate customer Identify the value stream to expose waste Create flow to reduce batch size and work-in-process Make only what the customer has ordered Seek perfection by continuously improving quality and eliminating waste

Types of Waste Overproduction Excess inventory Defects Non-value added processing Waiting Underutilized people Excess motion Transportation

Lean vs. Traditional Processes Half the hours of engineering effort Half the product development time Half the investment in machinery, tools and equipment Half the hours of human effort in the factory Half the defects in the finished product Half the factory space for the same output A tenth or less of in-process inventories Smaller lot sizes Increased capacity / throughput Higher inventory turns More available floor space Source: The Machine that Changed the World, Womack, Jones, and Roos, 1990.

Background and History (cont.) 1949: Taiichi Ohno promoted to shop manager at Toyota, develops “elimination of waste” concept 1951: Ohno refines TPS to include visual control, employee suggestions, TWI, batch size reduction, and kanban 1965: Toyota receives Deming Prize for Quality 1975: First English translations of TPS are drafted 1980-83: First books on TPS by American authors: Kanban and Zero Inventories 1990: Womack and Jones publish The Machine That Changed the World, becoming the definitive text creating the term “lean”, followed by Lean Thinking in 1996