Slide 1Slide 2The Evolution of Lean Manufacturing and Lean Sigma – TBM ConsultingKey Points from MovieSlide 5Recommended ReadingsSlide 7Slide 8The Past vs. NOWSlide 10Slide 11Slide 12Slide 13Origins of LeanThe Importance of a VisionFord Invents an Industry!Shortening the Production CycleFord Production Cycle - 1926Ford - Highland ParkSlide 20Deming’s Management PrinciplesDeming: Improved Quality Leads To:The Deming CycleTaiichi Ohno & Shigeo ShingoSlide 25Slide 26Spaghetti WorldLean Life CycleWhat is Lean Manufacturing?Lean Manufacturing – NIST, FORDLean Manufacturing – Womack & JonesJim Womack - What It Means to Think LeanLean ThinkingLean Is Market DrivenDefinition of Value addedLean = Eliminating wasteManufacturing’s Deadly SinsOverproductionSlide 39Inventory WasteWaitingWaste of TransportationProcessing WasteMotion WasteDefectsPeople WasteJim Womack - “This Too Shall Pass”Slide 48Definition of Standardized WorkWork Place OrganizationElements of a 5S ProgramVisual ControlsSlide 53The Visual WorkplaceSlide 55Lean Workforce Practices include:Quick ChangeoverSlide 58Batch Size ReductionPoint of Use StorageQuality at the SourceSlide 62“Push” ManufacturingPush vs. Pull SystemsPull SystemPull System Flow DiagramCellular ManufacturingBuilding the Cell: 5 step processSlide 69Step 2 -- Establish Takt TimeStep 3: Review Work SequenceStep 4 :Combine Work to Balance ProcessCell Step 5 - Plant Layout Design & ConstructFlexible Layouts for Variable Work CyclesTotal Productive Maintenance (TPM)Slide 76Continuous Improvement (CI)Barriers to ImprovementKeys to CI SuccessKeys to Success (Continued)Implementation Success FactorsBenefits of LeanTypical ObjectionsJim Womack - “Affording Lean”Value Stream MappingLean Building BlocksConclusionLean ManufacturingLean Manufacturing“Although still in its early stages, a revolution in production management is already taking place in the United States.Japan must not be allowed to fall behind.” Shigeo Shingoto the JMA, 1990Lecture 4 - PTTE 434, Quality Assurance, Management and OrganizationJim Wixson, InstructorOverview of Lean Manufacturing2University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorPTTE 434: Quality Assurance Organization & Management Outline– Lean Manufacturing•Origins of Lean Manufacturing & Definitions• Wastes in Manufacturing•Discuss Lean Building Blocks:•Standardized work•5S System•Visual Controls•Plant Layout•Teams•Quick Changeover•Batch Reduction•Point of Use Storage (POUS)3University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorThe Evolution of Lean Manufacturing and Lean Sigma – TBM ConsultingClick Here to See “Evolution of LClick Here to See “Evolution of Lean Manufacturing”ean Manufacturing”Click Here to See “Lean Sigma”Click Here to See “Lean Sigma”4University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorKey Points from MovieFundamentals of Lean learned from the Japanese at ToyotaAchieve productivity improvement in core business process.Better job rewardsNew thinkingMeasurement and powerful root cause analysis toolsOne piece flow – only way to have “waste speak to us.”Reduced inventory space – cell manufacturingSimplify, Simplify, Simplify!!!Retrained workers on other productsReduced inventory, reduced cost of quality, improved productivityIncreased market share5University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorPTTE 434: Quality Assurance Organization & Management Outline-Lean Manufacturing (continued)•Discuss Lean Building Blocks:•Quality at the Source•Pull/Kanban•Cellular/Flow•Total Productive Maintenance (TPM)•Implementation•Barriers to Improvement•Keys to Success•Benefits of Lean•Conclusion•Additional Resources6University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorRecommended ReadingsLean Thinking, by Jim Womack Becoming Lean, by Jeffrey Liker The Machine That Changed the World, by Jim Womack and Daniel T. Jones The Goal, by Eli Goldratt World Class Manufacturing: The Next Decade, by Richard Schonberger Other books/material can be found on the LEI.com or ProductivityInc.com7University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorObjectives:1. Know the difference between a push systems and pull system2. Realize the importance of work standardization3. Be able to identify manufacturing system wastes4. Know relevant terminology; JIT, kaizen, pull, kanban, etc.5. Understand workplace organization and visual manufacturing tools, i.e. (5S)6. Understand and be able to apply value stream mapping concepts7. Understand the importance of setup reduction and batch size reductionUnderstand the basics of lean manufacturing8University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorObjectives:Understand the benefits of point of use storageUnderstand total productive maintenance concepts and how to begin implementation of autonomous maintenanceUnderstand pull systems & kanbansBe able to calculate takt timesUnderstand manufacturing cell design, balancing and loadingBe aware of current lean manufacturing efforts in industryUnderstand the roles of employees and managersThe Past vs. NOWHigh unit volume, less varietyHigh qualityQuality lost due to people, poor work ethicSome defects acceptableHigher quality means higher costsQuality comes from inspectionSuppliers are adversariesQuality is a function of manufacturingDelivery & service importantEmployees do what they’re toldThe PastNOWBuyers market - international competitionFlexibility required due to varietyHigher qualityLow quality caused by management & systemsZero defects is the goalHigher quality means higher profitsCannot inspect quality inSuppliers are members of the teamQuality is everyone's jobDelivery & service vitalEmployees want influenceMaximize Asset utilization10University of Idaho, Idaho Falls, ID, Industrial Technology Program, PTTE434, J.R. Wixson - InstructorValues - Employee’s RoleNEWPermission to be wrongConceptualProductiveCreativeCommunicativeAssertiveEducatedPosting of performanceWit, humorA vital problem solverExperimentPaid by