1. 7 Types of Waste –C –Correction –O –Overproduction –M –Movement of Material & Information –W –Waiting –I –Inventory –P –Processing Lean Principle: Lean Principle: All waste is eliminated

2. Overproduction  There are 2 types of over-production: both are wasteful. One is producing a larger amount than the order requires. The other is producing goods at a rate faster than they are needed. # 1 (Overproduction is the most significant form of waste!)

3. #2 Correction  When work is not performed correctly the first time, resources are used to correct the defect. Resources are used again and again to address quality problems that may surface later

4. Motion  Any movement of people or machinery, which does not contribute added value to the product is considered waste. #3

5. Material Movement  Applies to the delivery of materials and parts to the supply of information. Any movement of material and product that does not support the “Just-In-Time” production is a form of waste. #4

6. Waiting  This is “idle” time that occurs in process line that is not efficiently organized; or when an operator must wait for a machine to complete an automatic process or for the delivery of parts to the workstation. #5

7. Inventory  Inventory must be adjusted to the actual need or the “JUST-IN-TIME” production schedule. An excess of parts between work processes or too many parts delivered by suppliers is considered waste. #6

8. Processing  Unnecessary processing of work does not improve the quality of the product. #7

9. Apply Lean to your Life Press Alarm Brush Teeth Get out of bed Walk to Kitchen Eat Breakfast Walk to Room Press Alarm Snooze Take Shower Find Clothes Find work Materials Put on Clothes Leave House 5 s 150 s300 s 20 s10 s5 s 30 s 300 s 30 s 20 s10 s 20 s300 s Total Cycle Time : 1200 s = waste

10. Apply Lean to your Life Press Alarm Brush Teeth Get out of bed Walk to Kitchen Eat Breakfast Take Shower Find work Materials Put on Clothes Leave House 5 s 150 s300 s 20 s 10 s30 s 10 s 300 s Total Cycle Time: 835 s 30% Improvement EXTRA 6 min a day!!! = 1.5 days a year 30%

11. Process Mapping

12. Understanding the use of Process Mapping.Understanding the use of Process Mapping. How to construct a Process Flow Chart.How to construct a Process Flow Chart. Understanding the use of Process Mapping.Understanding the use of Process Mapping. How to construct a Process Flow Chart.How to construct a Process Flow Chart. Objectives

13. Process Mapping Process Map is a graphical presentation of the flow of a process. A detailed process map contains information that is beneficial to improving the process

14. OPERATION TRANSPORTATION STORAGE INSPECTION DECISION

15. Good Bad Scrap Warehouse How many Operational Steps are there? How many Decision Points? How many Measurement/Inspection Points? How many Re-work Loops? Good Basic Process Flow