Becoming a Lean Enterprise
Lean Manufacturing and Implementation Program Schedule
Product Lean Assessment Five S Training Five S Implementation Kaizen Training Kaizen Work Shop Coordination Standard Work 3P Training 3P Implementation Management Review and Assessmentongoing ongoing ongoing ongoing ongoing Month 1 Month 2 Month 3 Month 4 Month 5 Month 6
What is 5S?
5S is the first initial of Japanese words, the translation of which is :
Seiri Seiton Seisko Seiketsu Shitsuke
= Sort = Set in order = Shine = Standardize = Self discipline
Seiri - Sort
Unnecessary tools, parts and supplies areremoved from the work area
Seiton - Set in order
A place for everything and everything is in its place
Seisko = Shine
The area is cleaned as the work is performed
Seiketsu = Standardize
Standard Set – Up Tooling In Place
Shitsuke = Self discipline
5S is a habit and is continually improved
Work areas are safe, organized, moreefficient and free of hazards and dangerous working conditions
IDENTIFY THE WASTE
Three types of Waste
Muda : Non-value added work Muri : Overburden Mura : Unevenness
Muda the 7 Deadly Wastes
1.Overproduction 2.Transportation 3.Waiting 4.Processing methods 5.Inventory 6.Motion 7.Defects
Waste exists in every formand in all areas of a manufacturing process. Lean Manufacturing Tools and Techniques aid in the rapid identification of waste elements and provides permanent solutions to improve the process.
When a business develops into a Lean Enterprise, the team will take a zealous approach to eliminating wasteful activities.
Available Working Time
Customer Demand • The rate ofproduction required to meet the customer’s demand rate.
• It’s used to synchronize the pace of production to match the pace of sales, to provide the target rate for production, targeted cycle actions, line balancing and bottleneck identification.
What is Kaizen?
A rapid, learn/do, rigorous and disciplined workshop
requiring detailed planning
and commitment to action
wherepeople who do the work
make changes which result in dramatic reductions
in cost and flow time.
How does Kaizen work?
• An area is selected • Detailed pre-planning is done • The team works together to implement improvements • Waste is identified and eliminated during the workshop • Little or no money is spent • It‟s a series of hits, not a home run
4-6 Weeks (recommended)
Phase 1 & 2 Phase 1: Evaluation
– – – – – Products and flow Processes Equipment Workplace Organization Demand Level
Phase 2: Planning
• • • • • Charter development Objectives and boundaries Data collection and documentation Workshop logistics Team memberselection
– Need for rapid improvement – Enthusiasm/spirit – Culture
Phase 3: Workshop “Week”
• • Thursday before workshop – Management briefing (1-2 hours) Friday before workshop – Lean Education day, including Standard Ops Tools – Process walk – Introduce teams, review charter Monday – Quickly review Charter – Process Sponsor verbalizes commitment to team – Takeaction - document/simulate/implement Tuesday through Thursday – Document/simulate/implement Friday – Final report out – Celebrate the team‟s success
Data Collection and Analysis Tools
Cause and Effect Chart Flow Chart