“Lean” =
= Elimination of all waste
Previously Just In Time
Fast, dependable, higher quality, operated at low cost
Capacity Utilisation =
= Only produce when needed, low inventory
Muda, Mura, Miri (Lean seeks to minimise them all)
Muda = Anything that adds cost but not value
Mura = Eliminating unevenness/irregularities in production process
Miri = Unreasonable work is imposed on workers/machines because of poor organisation
Fundamental areas of Lean Manufacturing
- Product design eg, standard parts
- Process design eg, set-up size reduction
- Human resources eg, hire multi-skilled workers
- Organisation eg, visible team performance measurement
Lean manufacturing techniques - Gamba Kanri workplace management
Implement and maintain standards to increase efficiency on shop floor.
BY: Kaizen, visual management
Set-up time reduction steps
Basic steps:
1. Preparation
2. Mounting
3. Measurements & calibration
4. Trial runs and adjustments
Single Minute Exchange of Dies (SMED)
All changeovers less than 10 minutes.
Separate internal and external set-up, convert as many tasks as possible to external.
Andon =
A worker presses a signal (light, screen, or sound) that alerts everyone when something goes wrong so it can be fixed right away.
Jidoka =
Make equipment/operation stop whenever an abnormal or defective condition arises.
- Prevents overproduction
Smallest machine concept =
Using several small machines instead of one large one
- Less waste
- Easier planned maintenance
- Allow simultaneous processing
Poka Yoke =
Fail-safing
eg. One-way valves, cannot be inserted into a line wrong way round
Production and Material control - Pull Scheduling
Work centres only authorised to produce when it has been signalled that there is a need.
- Small lot sizes
- Low inventory
- Guaranteed quality
Lean Purchasing
Requires predictable demand
Frequent deliveries of small quantities Controls and reduces inventory Reduces space, waste and material handling
Organisation for Change =
Setting up the organisation so change can actually happen, not just be planned.
- Clear leadership to drive change
- Defined roles and responsibilities
- Communication across departments
- Employee involvement and training
