Presentation on theme: "LEAN MANUFACTURING Jason Prior. Introduction to Lean Overview of Lean in Toyota video.video Main Concept: ELIMINATING WASTE Not an acronym Not."— Presentation transcript:
Introduction to Lean Overview of Lean in Toyota video.video Main Concept: ELIMINATING WASTE Not an acronym Not a new concept has been in development for over 200 years. Example: A Lean person is someone who is quick, has little fat, flexible and effective. The same can be said for a Lean organization.
Value Stream Value Stream videovideo Approximately 95% of a value stream is waste or non-value added time Value stream mapping visually maps the flow of materials and information through all processes until the product reaches the customer. Purpose of value stream mapping is to identify non- value added actions so they can later be improved/eliminated.
Types of Waste or Muda 1. Transportation 2. Inventory 3. Unused Creativity 4. Waiting 5. Overproduction 6. Complexity 7. Defects
Customer Pull and Kanban Systems A method of controlling the flow of production through the factory based on a customer’s demand Alternative to producing according to a forecast If you read this say I watch barney out loud now Implementation will reduce lead times, minimize work in process, optimize floor space usage, simplify production signals and improve on-time delivery to your customers.
Kanban Example Kanban mean “visual record” in Japanese An exampleexample
Just in Time Parts arrive through the supply chain shortly before they are needed for production Inventory Strategy that a business implements to reduce work in process (WIP). Must be coordinated with suppliers Saves Space
5S Organizing a Workplace Sort- red tagging; anti-just in case attitude Set in Order- "A place for everything and everything in its place." Shine- Clean so malfunctions easier to spot Standardize- simplify the process so easy to repeat and sustain Sustain- never finished
Continuous Improvement (Kaizen) Improvements should be made both radically and incrementally Radical improvements include overhauling a batch system into a flow system Incremental improvements focus on attacking waste in the value stream Vital to create a vision of the process and eliminate waste one step at a time to achieve the goal Compete against perfection as well as competitors.
Homework It is obvious that 5S is successful in manufacturing environments. However, watch this video and write two thorough responses on your opinion of 5S in an office environment. Choose two of the following topics: Would you mind “5S-ing” your desk space? Why or Why not? Do you think a 5S office space would make an employee more efficient/productive? Many people have their own organization methods. Would it be more effective to adopt 5S or allow employees free reign? http://online.wsj.com/article/SB122505999892670159.html#video=08 C6384E-D821-4E06-8D3C-7127672621CF&articleTabs=video
Rules 1. Divide into 2 equal teams 2. There will be 8 available questions to choose from. The two teams will alternate choosing and answering questions. 3. 1 st question =100 ; 2 nd question=200; 3 rd question =300 ; 4 th question =400 4. If a team answers incorrectly the other team has the chance to steal the points 5. Each team gets one Super Question which adds 200 points to the question’s value.