Lean as an improvement methodology has grown well beyond lean manufacturing only. Those on the cutting edge of improvement now drive to implement it at the Enterprise Level.
Lean is about eliminating waste and implementing continuous flow for products and information. It's based upon 5 core principles.
Lean manufacturing history now stretches over a century deep. Although first created for production environments, implementing lean is appropriate for service and office transaction environments.
Lean is based on simple principles and tools all aimed at eliminating or minimizing the eight types of "Lean" waste.
One of the primary goals of Lean Manufacturing is to eliminate waste. In order to eliminate waste we must first understand what “Lean" classifies as waste......
Waste 1: Waiting
Waiting for material and information is waste. Waiting is a delay and disruption in the process and interrupts flow.
Waste 2: Overproduction
Overproduction is producing too much or producing too soon. Overproduction consumes resources for things that the customer has not asked for and may not need.
Waste 3: Rework
Rework or repair is any change to the product or information after it's been made. Rework or repair result from things not done right the first time.
Waste 4: Motion
The waste of motion typically refers to the movement of a people. Unnecessary motion extends the time to complete the task.
Waste 5: Processing
Over-processing refers to information such as documents. Documents that require numerous approvals to move forward. Performing operations that the customer does not care about.
Waste 6: Inventory
Inventory is any material that is kept in a quantity above the minimum to get the job done. Inventory ties up money and compounds problems when quality issues are found.
Waste 7: Intellect
The waste of intellect is the failure to utilize the time and the talents of people properly.
Waste 8: Transportation
The last waste is transportation. Any movement of product or information is considered waste.
Eliminating waste and making operations more efficient overall will go a long way in making any business more successful. These companies exemplify lean manufacturing practices and have left industry with a blueprint on how to do it.
The first step of 5S is to organize the work area. Only those things that are used each day should be within the work area. Daily use items should be within arms reach if possible. Less frequently used items should be stored further away. Items never used should be removed all together.
After sorting productivity improvement is almost
The second step of 5S involves arranging the items that remain after
5S. Materials, tools and information, are arranged so that they are easy to find
by anyone. Good order facilitates efficient and mistake-free processes.
The third step of 5S is a good old fashion cleaning. Keep the area clean
and don't allow things to accumulate. Find preventive methods where you can to
keep the mess from happening in the first place.
The fourth step of 5S is to create a consistent method for carrying out 5S
tasks and procedures. Implement visual controls such as signs, boards, color
codes, schedules, etc.
The last step of 5S is to commitment to the change and sustain the improvement. Without “Sustaining”, the area will revert back to being disorganized. Implement roles & responsibilities.
5S is the foundation of the visual factory. In the visual factory you can tell what's going on just by looking around.
Envision that you're a new employee:
Kaizen is Japanese for "improvement" or "change for the better".The philosphy of Kaizen is that all processes should be conitually evaluated and improved. Kaizen improvement events are used to continuously improve in all lean practices.
Kanban is Japanese for "sign board" or "bill board". Kanban is a Lean Manufacturing technique that is used to "pull" the product or service through the process. Kanban tells us when to produce, what to produce, and how many to produce. Some signal examples are colored cards or empty containers. The visual signal "pulls" for replenishment. Kanban requires workload balancing.
May 10, 16 09:24 PM
A Quality Control Plan is a documented description of the activities needed to control a process or product. The objective of a QCP is to minimize variation.
May 10, 16 08:49 PM
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May 10, 16 07:28 PM
The Weibull distribution is applicable to make population predictions around a wide variety of patterns of variation.