Lean Concepts

8/2/2019 Lean Concepts

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Lean:

Process based on the

fundamental goal of

eliminating waste and

maximizing flow.

Lean Objectives and goals

Define value from

customer perspectives

Reduce waste/improvequality

Utilize employee

potential

Standardize work

Balance workflow and

processes

Continuous improvement


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8 sequential steps used to implement Lean

concepts

Commit to LeanChoose the Value Stream

Value Stream= is the collection of steps that is needed to produce what thecustomer want

Learn about Lean

Map the current stateMap out everything that you are doing now.

Identify Lean Metrics

Identify the time it takes to complete all processes

Map the future state

Map the minimal collection of steps that is needed to produce what the customerwant

Create Kaizen plans(kai means take part and zen means make good

Small daily improvements made improved by everyone

Implement kaizen plans


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4

What is Lean Manufacturing?

A systematic approach to the identificationand elimination..of?

all forms of wastefrom the value stream.


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5

TPS Definitions of Waste

1. Overproduction

2. Waiting, including time in queue

3. Transportation (between workstations, or between

supplier and customer)

4. Non-value-adding activities / Over Processing

5. Inventory

6. Waste motion7. Cost of poor quality: scrap, rework, and inspection


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Benefits of Lean Manufacturing

(1) Lower production cost higher profits andwages

Cost avoidance flows directly to the bottom line.

(2) Supports ISO 14001 and "green"manufacturing

Reduction of material waste and associateddisposal costs higher profits

(3) Shorter cycle times: make-to-order vs. make-to-stock


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7

Control Surface Approach

Process

Control Surface

Material Inputs Material Outputs

Energy Inputs Energy Outputs

The material and energy balance is

standard practice for chemical process

design. Outputs must equal inputs.

Material outputs, for example, include everything that

is thrown away, as well as the product.


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So..

Most of lean manufacturing is

common sense!


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We can conclude that,

Business activities can contain enormousquantities of built-in waste (muda, friction).

The greatest obstacle to the waste's removal isusually failure to recognize it.

Lean manufacturing includes techniques forrecognition and removal of the waste.

This delivers an overwhelming competitiveadvantage.

This we will read as

GREEN OPERATIONS.


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5S-CANDO

5S-CANDO, a systematic approach to cleaning andorganizing the workplace, suppresses friction.

Seiri = Clearing up "When in doubt, throw it out."

Seitori = Organizing (Arranging) "A place for everything and everything in its place."

Seiso = Cleaning (Neatness)

Shitsuke = Discipline

Seiketsu = Standardization (Ongoing improvement,holding the gains)


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5S Performance Excellence Model

Systematic-Systematic

Organization

Scrubbing clean

Self-Discipline-

Control

For which this one?

Customer Expectations

Sorting Visual

Placement

Standardizing

Control

Improved Quality

Improved Safety

Reduced costs

Consistent Deliveries

Improved Product/ Service

Options


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Major CPITools (6s) Kaizen Lean Description

Cp/Cpk 4 Process capability assessmentDOE 4 Design of experimentsSPC 4 Process control based on statistics and data analysisFMEA 4 Risk assessment toolRegression 4 Correlate effect one variable has on anotherProcess Map 4 4 4 Map process steps to communicate and identify opportunities5 whys /2 hows 4 4 4 Determinationmethods for root cause discovery

Pareto 4 4 4 Column chart ranking items highest to lowestFishbone 4 4 4 Cause / Effect Diagram5S 4 4 Elimination wasteVisual Mgmt 4 4 4 Emphasis on visual techniques to manage processPoka-Yoke 4 4 Error proofing techniquesSpagetti Chart 4 4Kanban 4 4 Material storage technique used to control processTakt Time 4 4 Determine pace or beat of a processStd Work 4 4 Evaluate tasks done during a process

SMED 4 4 Single minute exchange of dies - Quick machine set upTPM 4 Integrate maintenance strategy with processCellular Flow 4 Reduce inventory & cycle time thru process layout and pull

production techniques

Expand Process Improvement Program to Utilize Kaizen Tool Kit

Tool Kit Comparison


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WASHINGTON

Gen. Stanley A.McChrystal, the leader of American and

NATO forces in Afghanistan, was shown a

PowerPoint slide in Kabul last summer thatwas meant to portray the complexity of

American military strategy, but looked more

like a bowl of spaghetti.

Spaghetti

SPAGHETTI
http://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://spaghetty....docx/http://spaghetty....docx/http://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-perhttp://topics.nytimes.com/top/reference/timestopics/people/m/stanley_a_mcchrystal/index.html?inline=nyt-per


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Spaghetti Chartis used to detail the actual physical flowand distances involved in a work process. Processesthat have not been streamlined frequently are poorly laidout with work/product taking a path through the workarea that looks like a mass of cooked spaghetti.

To create a spaghetti chart you:

1. Create a scale map of a work station or work process2. Draw a line from the initial point of work to the next step

3. Continue until the work/product exits the work area

Examination of this resulting chart will show where

improvements are to be made

Spaghetti Chart


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Spaghetti Chart


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Waste Management

Waste Volume contents

Activity data collection (solid waste)

Waste categories

Overview of methodological issues and challengesin reporting


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Waste Volume1 Waste generation, composition and

management data

2 Solid waste disposal

3 Biological treatment of solid waste

4 Incineration and Open Burning of Waste

5 Wastewater treatment and discharge


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1. Activity data for solid waste

Waste generation, composition andmanagement data

encourage collection and use of country-specific

data (local conditions vary much; uncertainties for

default data large)

regional/country-specific default data on amounts,

management and waste composition

management data: solid waste disposal,incineration, composting and other (recycling)

consistent treatment across categories


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1. Activity data for solid waste1

Default waste categories: MSW, Sludge,

Industrial waste and Other

regional defaults for MSW components (paper,

food, wood, plastics, etc.)

defaults for carbon contents in the different waste

types

degradable organic carbon (SWDS) fossil carbon (incineration, open burning)


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2. Solid waste disposal

Significant source of methane Considerable time lag in emissions after disposal

- taken into account in the First order decay

model (revised from GPG2000; spreadsheet; can

be used for all Tiers) default parameters provided (updated values

- decay rates by climate zone)

default regional acitivity data (guidance howto estimate historical disposal)

methane recovery - guidance improved


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Provide data for HWP estimates

FOD model produces estimates on carbon storage

in SWDS

only long-term carbon storage estimated

also corresponding methane estimates

carbon storage taken into account in the

AFOLU/HWP section => long-term carbon storagereported as an information item in the Waste

sector


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Box 3: Tier 3

Estimate Emissions using

the IPCC FOD method

with default data to fill in

missing country-specific

data

Collect current wastedisposal data and

estimate historical

data using guidance

in Section 3.2.2.

Yes

No

No

No

Box 1: Tier 1

Estimate emissions

using country-specific

methods or IPCC FOD

method with country-

specific key parameters

and good quality

country-specific activity

data

Box 2: Tier 2

Estimate emissions using

the IPCC FOD methodwith default parameters

and good quality country-

specific activity data

Yes

Yes

Start

1Good quality country-specific activity data mean country-specific data on waste disposed in SDWS for 10 years or more.

2Key parameters mean DOC/Lo, DOCfand half-life time

3

See Volume 1 Chapter 4, "Methodological Choice and Identification of Key Categories" (noting Section 4.1.2 on limitedresources), for discussion ofkey categories and use of decision trees.

Are

good quality

country-specific activity

data on historical and currentwaste disposal1

available?

Arecountry-specific

models or key

parameters2

available?

Is

solid waste

disposal on land a key

category3?


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3. Biological treatment of solid waste

GHG (CH

4, N

2O) emissions from biological

treatment small (CO2 not taken into account

as of biogenic origin)

simple methdology - activity data times

emission factor (defaults provided for

composting and anaerobic digestion)

energy use of methane from anaerobic

digestion => emissions from combustion to be

reported in the Energy sector


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4. Incineration and open burning of waste

Waste-to-energy reported in the energy sector

CO2 from fossil waste fractions (plastics, waste oils,etc.), N2O and CH4

open burning - new category; important indeveloping countries


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5. Wastewater treatment and discharge

Improved guidance (incl. tier-structure)

wastewater and sludge - emissions duringtreatment estimated together (organic matter in

sludge disposed at SWDS, spread in agricultural

soils or incinerated subtracted) uncollected wastewater methodology

N2O - methodology also for industrial waste water

treatment

Documents

Lean Concepts