What is lean manufacturing?
it is aimed at the elimination of waste in every area of production including customer relations, product design, supplier networks, and factory management
What is the goal of lean manufacturing?
Reducing lead time by reducing waste and at the same time improve quality, reduce costs, improve moral, and improve safety
What is Lean
pioneered by toyota, focuses on the efficient operation of the entire value chain
What are the focus areas of lean
- remove non-value added steps to: reduce cycle time, and improve quality
- align production with demand
- reduce inventory
- improve morale, process safety and efficiency
What is six sigma
developed by motorale. It. can be defined as a :
- measure of process capability
- set of tools
- disciplined methodology
- vision for quality
- philosophy
- strategy
Focus areas of six sigma:
improving quality by controlling variation
What is 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 projects execution
The five principles of lean
- specify value from the standpoint of the customer
- idetify the value stream for each product and remove waste activities
- make value flow towards the customers as quickly as possible
- only at the pull of the customer
- while striving for excellence
Assessing the process map
Value add and non-value add. All process steps cost time and money, only a few add value
The steps in the process map
- Business value add (BVA)
- Non value add (NVA)
- Customer value add (CVA)
Customer value add (CVA)
- Does the task transform the product or service?
- Is that transformation meaningful to the customer?
- Would the customer be willing to pay?
Business value add (BVA)
- Does this task reduce financial risk?
- Does this task support financial reporting requirements?
- Would the process break down if this tasks were removed?
- Is this task required by law or regulation?
Non-value add (NVA)
- 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. It is a quality measurement tool that is used to determine which requirements are important
What are four types of customer needs?
- The ‘surprise & delight factors. These really make your product stand out from the others
- The ‘more is better’
- The ‘must be’ things. Without this, you’ll never sell the product.
- ‘Dissatisfiers’ are the things that cause your customers not to like your product
Lean (3)
- Fast -> from the moment the order is received till the moment the order is delivered
- Flexible -> low-cost flexibility by a batch size of one
- Flow -> working steadily at the customer rat
To goal of just-in-time
to minimize the presence of non-value-adding operations and non-moving inventories in the production line
Jidoka
“automation with a human touch”. Quality is built-in during the manufacturing process. When a problem occurs, the equipment stops immediately, preventing defective products from being produced
Just-in-time production (JIT)
Each process produces only what is needed by the next process in continuous flow
Lean production
production aimed at the elimination of waste in every area of production, Its goal is to become highly responsive to customer demand while producing top quality products in the most efficient and economical manner possible
Takt time
most efficient time for any product or service
Identify waste
- inventory
- overproduction
- material movement
- overprocessing
- waiting
- correction
- motion
