What is Lean?

It has to be invitation in front

Seminar on LEAN PRACTICES Dated

25-02-2016 time 12.00 to 1.00 p.m

Venue: Sarigam Industrial Association

                Shed No. C1/614,

                Road No.6,

                 GIDC,SARIGAM

What is Lean?

Lean is a management approach for creating value for the end customer through the most efficient utilization of resources possible. Its implementation often results in large cost reductions, improved quality, and increased customer service.

  1. Elimination of Waste: Waste is anything that does not add value to the system. This includes excess material, equipment, time, energy, space, or human activity that does not contribute to the value of the product or service being produced.
  2. A Broad View: All tasks and processes should be driven by one goal – to serve the customer.
  3. Simplicity: Lean emphasizes simple solutions to problems.
  4. Continuous improvement: The premise is that an organization is never perfect and can always improve in some way.
  5. Visibility: A clean environment creates order and improves performance.
  6. Flexibility: Flexibility means adapting to changes in the environment.

BENEFITS OF LEAN

·        COST

·        DEFECTS

·        LEAD TIME

·        WASTES

·        INVENTORY

·        OVER PRODUCTION

·       OVER PROCESSING

·        PROFIT

·        CAPACITY

·        QUALITY

·        CASH FLOW

·        CUSTOMER SATISFACTION

·        CUSTOMER RESPONSIVENESS

·       ON TIME DELIVERY

 

ELIMINATE WASTE. CREATE VALUE

 

32 ESSENTIAL LEAN MANURACTURING TOOLS
·        5s

·        Level Loading

·        ABC Inventory

·        Mind Maps

·        Andon

·        Muda (Waste)

·        Bottleneck Analysis

·        Overall Equipment Effectiveness (oEE)

·        Cellular Manufacturing

·        PDCA (Plan, Do, Check, Act)

·        Continuous Flow

·        Kaizen (Continuo’s Improvement)

·        Value Stream Mapping

·        Kanban (Pull System)

·        Visual Factory

·        KPI (Key Performance Indicator)

·        Poka-Yoke (Error Proofing)

·        ERP

·        Root Cause Analysis

·        Gama he Real Place

·        Single Minute Exchange of Die (SMED)

·        Heijunka (Level Scheduling)

·        Six Big Losses

·        Hoshin Kanri (policy Development)

·        Smart Goals

·        Ishikawa (Cause-E-Effect) Diagram & 5 whys

·        Standardized work

·        Jidoka (Autonomation)

·        Takt Time

·        Just In Time (JIT)

·        Total Productive Maintance (TPM)

·        Zero Quality Control

 

Waste In the Office

PROCESS WASTE PHYSICAL ENVIRONMENT WASTE PEOPLE WASTE
·        Approvals

·        Bottlenecks

·        Communication barriers

·        Competition (within the organization)

·         Defects

·         Extra features

·         Handoffs

·        Incompatible systems

·        Incomplete work

·        Inspections

·        Multitasking

·        Reviews

·        Rigid hierarchy

·        Shadow systems

·        Searching

·        Signatures

·        Task switching

·        Unnecessary complexity

·        Useless information

·        Variable flow in a process

·        Waiting/delays

·        Workarounds

 

·        Interruptions

·        Moving/transportation

·        Unsafe conditions

·        Information Waste

·         Converting formats

·        Data dead ends

·        Data discrepancies

·        Lack of usefulness

·        Manually checking electronic data

·        Metrics/measures

·        Missing Data

·        Re-entering data

·        Redundant data inputs

·        Redundant data inputs

·        Unavailable data

·        Unclear or incorrect data

·        Unknown data

Unnecessary data

PEOPLE WASTE
·        Ineffective meetings

·        Lack of project management

·        Lack of training

·        Lack of useful feedback

·        Mishandled conflict

·        Relearning

·        Turnover

·        Unclear roles

·        Unclear sponsorship, norms, & boundaries

·        Underutilized talent

·        Emotional waste: unnecessary frustration, stress

 

 

 



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