How does takt Time help? Provides a simple, consistent and intuitive method of pacing production. Is easily extended to provide an efficiency goal for the plant floor (Actual pieces / Target pieces). What is Total Productive maintenance? A holistic approach to maintenance that focuses on proactive and preventative maintenance to maximize the operational time of equipment. Tpm blurs the distinction between maintenance and production by placing a strong emphasis on empowering operators to help maintain their equipment.
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Helps to ensure that goals are effective. What is Standardized Work? Documented null procedures for manufacturing that capture best practices (including the time to complete each task). Must be living documentation that is easy to change. How does Standardized Work help? Eliminates waste by consistently applying best practices. Forms a baseline for future improvement activities. What is takt Time? The pace of production (e.g. Manufacturing one piece every 34 seconds) that aligns production with customer demand. Calculated as Planned Production Time / Customer Demand.
Replace bolts with knobs and levers) Eliminate non-essential operations Create Standardized Work instructions How does Single-minute Exchange of dies help? Enables manufacturing in smaller lots, reduces inventory, and improves customer responsiveness. What is Six Big Losses? Six categories of productivity loss that are almost universally experienced in manufacturing: Breakdowns Setup/Adjustments Small Stops Reduced Speed Startup Rejects Production Rejects How does Six Big Losses help? Provides a framework for attacking the most common causes of waste in manufacturing. What are smart goals? Goals that are: Specific, measurable, attainable, relevant, and Time-Specific. How do smart goals help?pdf
It is difficult (and expensive) to find all defects through inspection, and correcting defects typically gets significantly more expensive at each stage of production. What is root cause Analysis? A problem solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that only treat immediate symptoms of the problem. A common approach is to ask why five times each time moving a step closer to discovering the true underlying problem. How does root cause Analysis help? Helps to ensure that a problem is truly eliminated by applying corrective action to the root cause of the problem. What is Single-minute Exchange of dies? Reduce setup (changeover) time to less than 10 minutes. Techniques include: Convert setup steps to be external (performed while the process is running) Simplify internal setup (e.g.
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What is overall Equipment Effectiveness? Framework for measuring productivity loss for a given manufacturing process. Three categories of loss are tracked: availability (e.g. Slow cycles) quality (e.g. Rejects) How does overall Equipment Effectiveness help? Provides a benchmark/baseline and a means to track progress in eliminating waste from a manufacturing process.
100 oee means perfect production (manufacturing only good parts, as fast as possible, with no downtime). An iterative methodology for implementing improvements: Plan (establish plan and expected results) do (implement plan) Check (verify expected results achieved) Act (review and assess; do it again) How does pdca help? Applies a scientific approach to making improvements: Plan (develop a hypothesis) do (run experiment) Check (evaluate results) Act (refine your experiment; try again) What is poka-yoke? Design error detection and prevention into production processes with the goal of achieving essay zero defects. How does poka-yoke help?
How does kaizen help? Combines the collective talents of a company to create an engine for continually eliminating waste from manufacturing processes. A method of regulating the flow of goods both within the factory and with outside suppliers and customers. Based on automatic replenishment through signal cards that indicate when more goods are needed. How does Kanban help? Eliminates waste from inventory and overproduction.
Can eliminate the need for physical inventories (instead relying on signal cards to indicate when more goods need to be ordered). Metrics designed to track and encourage progress towards critical goals of the organization. Strongly promoted kpis can be extremely powerful drivers of behavior so it is important to carefully select kpis that will drive desired behavior. How do kpis help? The best manufacturing kpis: Are aligned with top-level strategic goals (thus helping to achieve those goals) Are effective at exposing and quantifying waste (oee is a good example) Are readily influenced by plant floor employees (so they can drive results) What is Muda? Anything in the manufacturing process that does not add value from the customers perspective. How does Muda help? The elimination of muda (waste) is the primary focus of lean manufacturing.
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After Jidoka, workers can frequently monitor multiple stations (reducing labor costs) and many quality issues can be detected immediately (improving quality). Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Relies on many lean tools, such. Continuous Flow, presentation heijunka, kanban, standardized Work and. How does Just-In-Time help? Highly effective in reducing inventory levels. Improves cash flow and reduces space requirements. A strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process.
A form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process. How does heijunka help? Reduces lead times (since each product or variant is holiday manufactured more frequently) and inventory (since batches are smaller). What is Hoshin Kanri? Align the goals of the company (Strategy with the plans of middle management (Tactics) and the work performed on the plant floor (Action). How does Hoshin Kanri help? Ensures that progress towards strategic goals is consistent and thorough eliminating the waste that comes from poor communication and inconsistent direction. Design equipment to partially automate the manufacturing process (partial automation is typically much less expensive than full automation) and to automatically stop when defects are detected. How does Jidoka help?
Continuous Flow help? Eliminates many forms of waste (e.g. Inventory, waiting time, and transport). A philosophy that reminds us to get out of our offices and spend time on the plant floor the place where real action occurs. How does Gemba help? Promotes a deep and thorough understanding of real-world manufacturing issues by first-hand observation and by talking with plant floor employees.
Standardize (write standards for above sustain (regularly apply the standards how does 5S help? Eliminates waste that results from a poorly organized work area (e.g. Wasting time looking for a tool). Visual feedback system for the plant floor that indicates production status, alerts when assistance is daddy needed, and empowers operators to stop the production process. How does Andon help? Acts as a real-time communication tool for the plant floor that brings immediate attention to problems as they occur so they can be instantly addressed. What is Bottleneck Analysis? Identify which part of the manufacturing process limits the overall throughput and improve the performance of that part of the process.
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There are a lot of great ideas to explore in lean. So where should you begin? One way to start is to survey the most important lean tools, with a brief description and salon short explanation of how each tool can improve your manufacturing operations. If a tool captures your interest or resonates with you in some way explore it further to decide if it is something to pursue nowor later. Many of these tools can be successfully used in isolation, which makes it much easier to get started. On the other hand, the benefits will compound as more tools are used, as they do support and reinforce each other. Organize the work area: Sort (eliminate that which is not needed). Set In Order (organize remaining items). Shine (clean and inspect work area).