Ten Steps to
Lean Production
Steps to CIM
1. Re-engineer (revisit,
replan)
the manufacturing
system
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Form U-cells to
produce families of
parts (clusters)
Integrate production,
inventories, Quality
Control and machine
tools
Steps to CIM
2. Setup reduction or
elimination
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Identify elements that
are “internal” and those
that are “external”
Improve methods (use a
pit crew)
Re-engineer to
eliminate adjustments,
mechanize, automate
Steps to CIM
3. Integrate quality control
into the system
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Develop a systems
approach
Incorporate visual signals
Work toward a “1 piece
flow”
Make 1, check 1, move 1 on
Steps to CIM
4. Integrate preventative
maintenance into the system
•
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•
Reduce pressure on workers and
the process (back off from 100%)
Housekeeping – place for everything
and everything in place
Decrease system variability
Learning Loops in CIM
Steps to CIM
5. Level, balance, sequence and
synchronize
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•
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“Smooth” manufacturing
Keep production “level”
Make production “predictable”
Incorporate “kanban” labelling
Label
Steps to CIM
6. Production Control
•
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Integrate scheduling and control functions
into the system
Use MRP/ERP software
Use the PC system to link cells together
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•
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MRP = Manufacturing
ERP = Enterprise
DRP = Distribution
CRP = Capacity
BRP = Business
Schematic factory layout
Steps to CIM
7. Reduce work-in-process
•
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•
Excess inventories hide problems
Reduce the inventory to expose
problems
Take immediate action to eliminate the
problems
Steps to CIM
8. Integrate suppliers
•
•
•
•
Work to reduce suppliers to a single
source
Develop trust & open communications
Implement flexible procurement
(supply purchasing) contracts
Develop long-range forecasts
Steps to CIM
9. Automation
•
•
•
•
Allow workers to control the process
(trust in work force)
Provide clear directions
In-process controls and inspections
Feedback loops
Steps to CIM
10. Computer-Integrated
Manufacturing
• Enterprise-wide systems
• Remove functionality
(independence) of departments
• Focus teams on product lines
and customers
The REAL Goal is to
become LEAN
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•
•
•
•
Waste eliminated
Employees involved
Customers satisfied
Profits increased
Company survival assured
By printing and binding in the
same factory, Butler and Tanner
reduces the amount of transport
required during the production
process
Achieving CIM
• Toyota has been on a
“journey” toward a
waste free and
coordinated operation
for 45 years… and
they know they are
not there yet.
• The “steps” and
“tools” help people
understand the
process of change,
but there is much
more that is required