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Lean Manufacturing
Chapter 15pp. 438-466
June 29, 2012
Lean Manufacturing
• Definition– Elimination– Waste– Continuous improvement
• 3 pronged approach– “Relentless” focus on quality– Eliminate waste– Involve employees
Lean Manufacturing
• “A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.”
Lean Manufacturing
• Key principles– Value– Value stream
• “mapping”
– Flow– Pull– Perfection
• culture
Lean Manufacturing
• Benefits– Lead time reduction– WIP reduction
1 day
2 days1 day
14 days
45 minutes
60 minutes
30 minutes
Lean Manufacturing
• Benefits– Lead time reduction– WIP reduction– Quality improvement– Space utilization – Greater customer satisfaction
“A systematic approach to identifying and eliminating….”
• Value stream mapping
“A systematic approach to identifying and eliminating….”
• Value stream mapping
“…waste (non-value added activities) …”
• 8 wastes of lean– Overproduction– Inventory– Waiting– Defects– Extra processing– Excessive motion– Transportation– Underutilized employees
“…waste (non-value added activities) …”
• 8 wastes of lean– Overproduction– Inventory– Transportation– Excessive motion– Extra processing– Defects– Waiting– Underutilized talents
“non-value added activities”
• Value-added activities– Transforms or shapes material or information– Customer wants it– Done right the first time
• Machining• Assembly• Painting• Sewing
“non-value added activities”
• Non-value added activities– Consume resources but create no value for customers– Could be stopped and it would be invisible to the
customer
“…through continuous improvement …”• kaizen• Satisfying the customer• People = most important resource• Quality at the source
“…through continuous improvement …”• 5S’s
– Sort– Stabilize (set in order)– Shine– Standardize– Sustain
(Stabilize)
Stability
Stability
Stability
Stability
• Traditional layout• Cellular layout
Stability
Lathe Mill Mill InspectDrill
Drill
TestDrillPack
1 2 3 4 5
10 9 8 7
6
27 Seconds 27
Seconds
Inspect
27 Seconds
(Stabilize)
“…by flowing the product at the pull of the customer…”
• Just-in time– Pull system (vs push)– Quick changeover (Set-up Reduction)
“…by flowing the product at the pull of the customer…”
• Pull system– Production based on actual consumption– Small lots– Low inventories– Management by sight– Better communication
Pull System
• Kanban
Pull System
• Kanban• Supermarket
Quick Changeover (Set-up Reduction)
Single minute exchange of dies (SMED)
Quality at the Source
• Source inspection• Means to inspect• Samples or established standards• Process documentation• Mistake proofing
Quality at the Source
• Source inspection• Means• Samples or established standards• Process documentation• Mistake proofing• Andon
Standardization
• Standardized work
Involvement
• Teams– with rotation of highly specified jobs
• Cross trained/multi-skilled employees– can work many operations within a cell and
operations in different cells
Stability
Lathe Mill Mill InspectDrill
Drill
TestDrillPack
1 2 3 4 5
10 9 8 7
6
27 Seconds 27
Seconds
Inspect
27 Seconds
Involvement
• Teams– with rotation of highly specified jobs
• Cross trained/multi-skilled employees– can work many operations within a cell and
operations in different cells• Continuous improvement philosophy• Process quality, not inspection• Use of participatory decision making
Why do it?
• Reduced inventory• Improved quality• Lower costs• Shorter lead time• Increased productivity• Greater flexibility• Greater customer satisfaction
Last comment
• Lean and Six Sigma• “hand and glove”
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