CONTINUOUS IMPROVEMENT PROGRAM
Lean
Manufacturing
Our company continues to grow
at 15% to 20% each year.
OUR CUSTOMERS WILL SAY
“Hasta La vista baby !!”
Our inventory in the stock room
grows.
$$$$$$$$$$$$$$$$$
How do we grow ?
How do we make the right product
on time ?
How do we lower our stock room
inventory ?
How do we maintain a good
quality product ?
We could hire more people
and buy more machines.
This would cost us $$$$
We could raise the price of our
products.
Currently our customers are asking us
to REDUCE the price of our products!
BEFORE WE DO ANYTHING ELSE
We need to become more
efficient in our manufacturing.
AND
We need to find waste in our
process and cut it out.
> Produce more product using
our current resources.
> Lower our stock room inventory.
> Accurately forecast exactly how long it takes to
make our products and ship them on time.
> Get all of the needed parts to Assembly at
the right time.
What is
LEAN
A systematic approach to identifying and
eliminating waste through continuous
improvement in pursuit of perfection.
Striving to do more with less, and do it
consistently.
Work Smarter Not Harder
TEAMWORK
FORM A TEAM OF PEOPLE,
THE PEOPLE THAT ACTUALLY
DO THE WORK
OBSERVE
IDEAS
ANALYZE THE CURRENT
SITUATION
THE TEAM DEVELOPS IDEAS
ON HOW TO ELIMINATE WASTE
COMMUNICATION
CULTURE
MAKE SURE EVERYONE KNOWS
THE GOALS, THE CHANGES
BEING MADE, THE SUCCESSES,
AND THE FAILURES
CREATE A CONTINOUS
IMPROVEMENT CULTURE.
ALWAYS CONSIDER NEW IDEAS
8 Forms of Waste
DEFECTS
WAITING
Any non-work time
waiting for tools,
supplies, parts, etc..
Repair or
Rework.
Any wasted motion
to pick up parts or
stack parts. Also
wasted walking.
PROCESSING
Doing more work than
is necessary.
UNDERUTILIZED
PEOPLE
Types
of
Waste
Waiting for more
Work to do.
INVENTORY
Maintaining excess
inventory of parts in
process, or
finished goods.
EXCESS
MOTION
OVERPRODUCTION
Producing more
than is needed
before it is needed.
TRANSPORTATION
Transporting parts, or
finished goods into or
out of storage, or
between processes.
We
the operations.
We
We
the operations.
the operations.
VALUE STREAM MAP
FINDING WASTE
LEAN TOOL BOX
5S
TOOLS
SORT, SET IN ORDER,
SHINE, SET RULES, SUSTAIN.
TEAMS
STANDARDIZED WORK
PRACTICES
VISUAL CONTROLS
PLANT
LAYOUT
QUICK
CHANGEOVER
BATCH
REDUCTION
QUALITY AT
THE SOURCE
POINT
OF USER
STORAGE
PRODUCTION
CELL
SUPERMARKET FLOW
PULL SYSTEM
TOTAL PRODUCTIVE
MAINTENANCE
Kaizen
Kaizen Event
The definition of “Kaizen” has been
Americanized to mean "Continual
Improvement." A closer definition of the
Japanese meaning of Kaizen is "to take
apart and put back together in a better
way."
ISOLATION
“Do you have
any ideas ?”
“What problems
Can we solve ?”
“How can we make
this better ?”
SECRECY
“Here’s what
we are doing”
“Here’s where
We are going”
COMMUNICATION