Design Management can mail you a free assessment instrument that
you and your management team can use to evaluate your readiness
to go lean.
For this assessment or for more information on A Total Lean System
call Valerie Perez or David Drinnon toll free at 888-711-9988
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Creating
The Lean Culture
What is Lean?
Lean Manufacturing is a production strategy that aims to build products
and provide service with less effort and fewer materials, in less
time. It results in a Just-In-Time process flow geared toward meeting
the ever-increasing demands and expectations of the customer. The
focus is to eliminate all waste from processes, which in turn leads
to increased productivity and cost reduction. In today’s tough,
competitive markets, that is real value. The term “lean”
was coined and patterned after the reputable Toyoda Production System
that has revolutionized manufacturing and continues to set the pace
for world class production systems.
What are the Steps to a Total Lean System?
There are 5 foundational steps that must be implemented before you
can accomplish
Total Lean and realize its many benefits:
- Create The Lean Culture
- Maximize The Lean Team
- Organize The Lean Work Environment
- Establish The Lean Process
- Make Ongoing Lean Improvements
The Lean Conversion Begins With Creating
The Culture
Management and employees understand, embrace, and wholly commit
to Lean as a way of day-to-day living in the workplace. This process
includes:
- Thinking Lean
- Establishing a Lean Vision and Mission
- Supporting Lean
- Performing a Lean Assessment
- Getting Ready for Lean
Learning Lean: Technical and Social
Skills
- Maximizing The Lean Team
- Strong communication exists at all levels
of the organization. Effective management,
- ffective teams, and effective leadership
principles are integrated around prioritized
- Customer focus and supply chain management.
- Communication in a Lean Environment
- Effectively Building and Managing Lean Teams
- Being an Effective Team Member
- Lean Leadership Principles
- Lean Relationships: Customers and Suppliers
Organizing The Lean Work Environment
All of the obvious and not so obvious forms of waste are eliminated,
and clear visual controls are utilized throughout the workplace.
Work is standardized and promotes maximum safety and ergonomics.
The use of Value Mapping serves to evaluate processes, perform value-added
analysis, and establish more effective process flow.
- 5S
- Value Mapping
- Standardization of Work
- Visual Controls
- Feedback Systems
- Safety / Ergonomics
Establishing The Lean Process
Effective and efficient process flow based on customer demand and
pull is at the heart of lean manufacturing. All forms of non-value
adding elements, especially excess inventory and material handling,
are eliminated. Techniques such as Kanban, Quick Changeover, Cellular
Manufacturing, and Total Productive Maintenance are incorporated
into the process. In a lean process, defects are minimized, if not
totally eliminated, through the use of an effective Quality System
that maximizes autonomous quality control applications.
- Demand Flow: Internal and External
- Pull System
- Kanban
- One Piece Flow
- Inventory Management
- Quick Changeover (SMED)
- Cellular Manufacturing
- Total Productive Maintenance (TPM)
- Quality Control
Making Lean Improvements
Lean Manufacturing incorporates the concept of continuous improvement.
Once an organization undergoes the lean conversion, work is never
done; lean is a daily lifestyle. On an ongoing basis, team-based
Kaizen Events are conducted on an ongoing basis to further eliminate
waste, combine work to increase efficiency, and solve problems.
Error-proofing devices are implemented to prevent the production
of defects, and the constraints in the process are minimized, if
not removed all together. An improvement strategy such as Six Sigma
guides and prioritizes the cost reduction and improvement activities.
- Waste Elimination
- Kaizen
- Work Combination
- Problem Solving
- Error Proofing
- Constraints Management
- Six Sigma
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