What is Lean Manufacturing?
- Lean production is aimed at the elimination of waste in every area of production including customer relations, product design, supplier networks, and factory management.
- We should eliminate pure waste and strive to eliminate (or significantly reduce) necessary waste all the time.
What is the goal of Lean?
Reducing lead time by reducing waste.
- At the same time we strive to improve quality, reduce costs, and improve morale and safety.
What is the focus of Lean?
Focuses on the efficient operation of the entire value chain.
Focus areas:
- Reduce cycle time
- Improve quality
- Align production with demand.
- Reduce inventory.
- Improve morale, process safety, and efficiency.
What is the focus of Six Sigma?
Six Sigma is a measure of process capability focused on improving quality by controlling variation
Lean Six Sigma
Lean Six Sigma is a combination of two powerful and proven process improvement methods Lean and Six Sigma, that builds on existing organization capability in quality, statistics, and project execution.
What are Customer Value Add activities?
- Assembly
- Service delivery
- Call responding
- Fabricating
- Printing
What are Business Value Add activities?
- Order/entry processing
- Purchasing
- Sales/marketing
- Regulatory reporting
- Internal financial reporting
What are Non-Value Add activities?
- Handling
- Inspecting
- Transporting
- Stocking
- Rework loops
- Signoffs
- Delays
What are CVA questions?
- Does the task transform the product or service?
- Is that transformation meaningful to the customer?
- Would the customer be willing to pay?
What are BVA questions?
- Does this task reduce financial risk?
- Does this task support financial reporting requirements?
- Would the process break down if this task were removed?
- Is this task required by law or regulation?
What are NVA questions?
- If the customer knew we were doing this, would he want to pay less?
- Does the task fit into either of the other two categories?
- Can I reduce this activity?
What is a Kano Analysis?
- Kano analysis is a quality measurement tool used to prioritize customer requirements based on their impact on customer satisfaction, and determine which requirements are important.
- All identified requirements may not be of equal importance to all customers.
What are the four types of customer needs?
- The “Surprise and Delight” factors
- The “More is Better”
- The “Must be” things
- “Dissatisfiers”
What are the “Surprise and Delight” factors?
These really make your product stand out from the others.
What are the “Must be” things?
Without this, you’ll never sell the product.
What are the “Dissatisfiers”?
The things that cause your customers not to like your product.
What are the types of waste?
- Inventory
- Waiting
- Overproduction
- Overprocessing
- Material movement
- Motion
- Correction
What is inventory waste?
Any supply in excess of one piece flow.
What is waiting as waste?
Being idle between operations
What is overproduction?
Producing more or sooner than the customer needs.
What is overprocessing?
Extra efforts that add no customer value to the product.
What is material movement as a waste?
Moving material not needed for “Just-In-Time” production.
What is motion as a waste?
Any movement that adds no value
What is correction as a waste?
Failing driven activities: Inspection, Rework, Testing, Scrap
