LEAN PRODUCTION or Lean manufacturing or Toyota Production Sys...

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Sustainable Growth: Efficiency Improvement

Lean Production
Doing More With Less
By: Vadim Kotelnikov Founder, Ten3 Business e-Coach Inspiration and Innovation Unlimited!

See the Big Picture first

Lean Enterprise: 13 Tips

Kaizen Culture: 8 Key Elements

"The most dangerous kind of waste is the waste we do not recognize." ~ Shigeo Shingo

More Lean Production Quotes

"
What is Lean Production?
Lean is about doing more with less: less time, inventory, space, labor, and money. "Lean manufacturing", a shorthand for a commitment to eliminating waste, simplifying procedures and speeding up production. Lean Manufacturing (also known as the Toyota Production System) is, in its most basic form, the systematic elimination of waste overproduction, waiting, transportation, inventory, motion, AdChoices over-processing, defective units and the implementation of the Free Lean Mfg concepts of continuous flow and customer pull. eBook Five areas drive lean manufacturing/production: 1. 2. 3. 4. 5. cost quality delivery safety, and morale.

Overview of Pull Systems, KanBan & Lean Manufacturing Concepts

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Inventory Planning
Reduce safety stock

Just as mass production is recognized as the production system of more than 10% with the 20th century, lean production is viewed as the production Inventory system of the 21st century.

Optimization.

Benefits of Lean Production

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Establishment and mastering of a lean production system would Six Sigma Training allow you to achieve the following benefits: India Waste reduction by 80% Six Sigma certification Production cost reduction by 50% Manufacturing cycle times decreased by 50%

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The Seven Wastes To Be Eliminated

1. Overpoduction and early production producing over customer

Capacity in current facilities increase by 50% Higher quality Higher profits

requirements, producing unnecessary materials / products

2. Waiting time delays, idle time (time during which value is not added to the product) 3. Transportation multiple handling, delay in materials handling, unnecessary handling 4. Inventory holding or purchasing unnecessary raw materials, work in process, and finished goods 5. Motion actions of people or equipment that do not add value to the product 6. Over-processing unnecessary steps or work elements / procedures (non added value work) 7. Defective units production of a part that is scrapped or requires rework... More

Higher system flexibility in reacting to changes in requirements 1,000 Yrs Lean improved More strategic focus

Experience
in the company that 1,000% ROI from TPS
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Improved cash flow through increasing shipping and billing invented Lean frequencies However, by continually focusing on waste reduction, there are truly experts no end to the benefits that can be achieved.

8 Best Practices of Successful Companies The Five Elements of Enabling a Lean Approach
1. 2. 3. 4. 5. Specify Value Identify and Map the Value Stream Flows Pull Perfection... More

Transitioning Your Company To a Lean Enterprise

13 Tips Begin with action in the technical system and then follow quickly with cultural change... More

The Toyota Way: 14 Principles

The Toyota Way is not the Toyota Production System (TPS). The 14 Principles of the Toyota Way is a management philosophy used by the Toyota corporation that includes TPS, also known as lean manufacturing. TPS is the most systematic and highly developed example of what the principles of the Toyota Way can accomplish. The Toyota Way consists of the foundational principles of the Toyota culture, which allows the TPS to function so effectively... More

Kaizen and Lean Manufacturing Kaizen is the heart of the Toyota Production System. Toyota states: "...based on the concept of
continuous improvement, or Kaizen, every Toyota team member is empowered with the ability to improve their work environment. This includes everything from quality and safety to the environment and productivity. Improvements and suggestions by team members are the cornerstone of Toyota's success."... More

Implementing Kaizen: 7 Conditions Quick and Easy Kaizen

Quick and Easy Kaizen helps eliminate or reduce wastes, promotes personal growth of employees and the company, provides guidance for employees, and serves as a barometer of leadership. Each

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LEAN PRODUCTION or Lean manufacturing or Toyota Production Sys...

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kaizen may be small, but the cumulative effect is tremendous. The quick and easy kaizen process works as follows: 1. The employee notices a problem or an opportunity for improvement... More

Case in Point Canon

Eliminating 9 Wastes The objectives of Canon Production System (CPS) are to manufacture better quality products at lower cost and deliver them faster.

3 Strategies of Market Leaders

Canon invited all their employees to suggest ideas for improvement and developed 6 Guidelines for the Suggestion System to make it most effective. The company developed also a list of 9 wastes to AdChoices help their employees become problem-conscious, move from Want Profit operational improvement to systems improvement, and recognize Improvement? the need for self-development... More Higher Profit Five Ss at Canon existing Resources Canon has an ongoing workplace improvement program called the Lean Management Five Ss. The Five Ss refer to the five dimensions of of workplace India Singapore ME optimization: Seiri (Sort), Seiton (Set in order), Seiso (Shine), sfccostmanagement.com Seiketsu (Standardize), and Shitsuke (Sustain)... More

Toyota Production System (TPS)

7 Principles 1. Reduced Setup Times 2. Small-Lot Production 3. Employee Involvement and Empowerment 4. Quality at the Source 5. Equipment Maintenance 6. Pull Production 7. Supplier Involvement... More

Lean Production Overview

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Focus on continuous improvement of processes rather than results - of the entire value chain Dell Business The lean manufacturing mindset: concept, way of thinking not Wide Range of techniques; culture not the latest management tool Continuous product flow is achieved through physical More! rearrangement and system structure & control mechanisms

Laptops

Business Laptops w/ Intel Core. Know

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Single-piece flow / small lot production: achieved through equipment set up time reduction; attention to machine High Return on maintenance; and orderly, clean work place Investment Pull reduction / Just-in-Time inventory control

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Basic Elements of Lean Manufacturing

The basic elements are waste elimination, continuous one piece workflow, and customer pull. When these elements are focused in Artes expression the areas of cost, quality and delivery, this forms the basis for a lean systems production system. for the production of The lean production concept was to a large extent inspired by the recombinant proteins Kaizen the Japanese strategy of continuous improvement. in microbial systems Employee empowerment and promotion among them of a way of www.artes-biotechnology.com thinking oriented at improving processes, imitation of customer relationships, fast product development and manufacturing, and collaboration with suppliers are the key strategies of leading lean companies.

Characteristics of a Lean Enterprise Kaizen Mindset

Not a single day should go by without some kind of improvement being made somewhere in the company... More Integrated single piece continuous workflow Close integration of the whole value chain from raw material to finished product through partnership oriented relations with suppliers and distributors.

Just-in-time processing: a part moves to a production operation, is processed immediately, and moves immediately to the next operation Short order-to-ship cycles times; small batch production capability that is synchronized to shipping schedules Production is based on orders rather than forecasts; production planning is driven by customer demand or "pull" and not to suit machine loading or inflexible work flows on the shop floor. Minimal inventories at each stage of the production process Quick changeovers of machines and equipment allow different products to be produced with one-piece flow in small batches Layout is based on product flow Total quality control. Active involvement by workers in trouble shooting and problem solving to improve quality and eliminate wastes. Defect prevention rather than inspection and rework by building quality in the process and implementing real time quality feedback procedures. Team-based work organizations with multi skilled operators empowered to make decisions and improve operations with few indirect staff.

Applications
Lean techniques are applicable not only in manufacturing, but also in service-oriented industry and service environment. Every system contains waste, i.e. something that does not provide value to your customer. Whether you are producing a product, processing a material, or providing a service, there are elements which are

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LEAN PRODUCTION or Lean manufacturing or Toyota Production Sys...

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Key Features of Lean Production

compared to Traditional Mass Production Reduced Setup Cost and Times (for semi-versatile machinery such as big stamping presses) from months to hours thus making small-lot production economically viable; achieved by organizing procedures, using carts, and training workers to do their own setups, Small-Lot Production allowing higher flexibility and pull production (or just-in-time manufacturing) Employee Involvement and Empowerment organizing workers by forming teams and giving them training and responsibility to do many specialized tasks, for housekeeping, quality inspection, minor equipment repair and rework; allowing also them time to meet to discuss problems and find ways to improve the process Quality at the Source total quality management (TQM) and control; assigning workers, not inspectors, the responsibility to discover a defect and to immediately fix it; if the defect cannot be readily fixed, any worker can halt the entire line by pulling a cord (called jidoka) Pull Production, or Just-In-Time (JIT) the method wherein the quantity of work performed at each stage of the process is dictated solely by the demand for materials from the immediate next stage; thus reducing waste and lead times, and eliminating inventory holding costs Continuous Equipment Maintenance as pull production reduces inventories, equipment breakdowns must also be reduced; thus empowered operators are assigned primary responsibility for basic maintenance since they are in the best position do detect signs of malfunction Multi- Skilled Workforce as employees are empowered to do many jobs, they must be provided with adequate training Supplier Involvement the manufacturer treats its supplier as a long-term partners; they often must be trained in ways to reduce setup times, inventories, defects, machine breakdowns, etc. in order to enable them to take responsibility for delivering the best possible parts/services to the manufacturer in a timely manner.

considered 'waste'. The techniques for analyzing systems, identifying and reducing waste, and focusing on the customer are AdChoices Real time applicable in any system, and in any industry. Lean thinking may also be applied for getting rid of bureaucracy in your home office. To run your home office more effectively and faster you may need just as little as 10% of its current staff. Only executives who have a direct involvement with finding, keeping, or growing customers as well as key support staff - accountants, tax, legal and human resources people should stay. Others can be rehabilitated by sending to an operating unit.

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Three Stages of the Suggestion System

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1. Encouragement. In the first stage, management should make Franchise. Make A every effort to help the workers provide suggestions, no matter how primitive, for the betterment of the worker's job and the workshop. Difference While You This will help the workers look at the way they are doing their jobs... Make Money!
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Managing processes
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Strategy of Lean Production

Lean customer relationships Lean product development Lean manufacturing/order fulfillment Lean supply chain

Lean System Components and Best Practices

1. Cultural awareness 2. Workplace organization 5S (sort - straighten - sweep - standardize self-discipline) & visual control

Case in Point 14 TQM Slogans at Pentel

Pentel is a Japanese firm manufacturing stationary products. The following is a list of 14 Pentel's slogans for explaining Total Quality Management (TQM) and Quick and Easy Kaizen philosophy to its employees. Be problem-conscious at all times... More

3. Standardized work 4. Flexible operations 5. Employee empowerment and continuous improvement (see also
Kaizen)

Areas Targeted by TQM in Japan 8 Best Practices of Successful Companies

Manage inventory in superior fashion... More

6. Quick changeover capability 7. Total quality management & total productivity maintenance 8. Error proofing 9. Material control 10. Level production

Case in Point IBM

IBM regularly compare part counts, bills of materials, standard versus custom part usage, and estimated processing costs by tearing down competitor products as soon as the latter are available. "Through such tear-downs during the heyday of the dot matrix printer, IBM learned that the printer made by the Epson, its initial supplier, was exceedingly complicated with more than 150 parts. IBM launched a team with a simplification goal and knocked the part count down to 62, cutting assembly from thirty minutes to only three."
1

Traditional Manufacturing
Scheduling Production Lead Time Batch Size Inspection Layout Empowerment Inventory Turns Flexibility COGS Forecast - push Stock Long Large - Batch & Queue Sampling - by inspectors Functional Low Low - <7 turns Low High and Rising

Lean Manufacturing
Customer Order - pull Customer Order Short Small - Continuous Flow 100% - at source by workers Product Flow High High - 10+ High Lower and Decreasing

TPS-Lean Six Sigma

TPS-Lean Six Sigma is like a turbo-charged Lean Six Sigma program. TPS-Lean Six Sigma is a revolutionary, holistic concept. It actively has human capital embedded in Lean Six Sigma in a manner that not only stimulates commitment, integrity, work-life balance, passion, enjoyment at work and employee engagement but also stimulates individual and team learning in order to develop a motivated workforce and sustainable performance improvement and quality enhancement for the organization... More

Focusing on Main Principles As The Key To Success

"In the U.S., becoming Lean appears to have gone down a path of implementing tools such as one piece flow, value stream mapping, standardized work, or kaizen events, but results have not always followed. Toyota, by way of contrast, has stayed focused on its principles and a disciplined emphasis on process improvement to obtain results such as making a profit, reducing lead-time, improving productivity, achieving built in quality, as well as respecting human dignity of employees etc. The difference may sound trivial, but it is actually significant. In fact, it is likely the main reason why Toyota has continued to see success on so many dimensions, where others struggle." (Art Smalley )
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