Muda (Waste)
Lean - A systematic approach to identifying and eliminating waste( 5
7types of muda (storage,transportation,waiting,motion,process,defects,over-
Value - Specific product that meets a customer’s needs p ro d u ctio n )
Key Principles (value, value stream, flow, pull, perfection)
Sort—
Keep what you need, get rid of the rest
Value Stream - Set of specific actions required to bring a specific Straighten—
Organize what’s left
Aclean workplace is m o re efficient
3 critical management tasks (problem solving (design) , information
Scrub—
Finda best wayandhave ev ery o n e d o it th at w ay
management (scheduling), physical transformation (raw)
Standardize— Sustain—
Don’t
let up
Flow - Parts “flow” through a Value Stream
Jidouka –perform ongoing quality assurance
Upstream “head” of the flow
Downstream “mouth” of the flow, where the p art is p u lled by the customer
Kanban: Cardor other device that communicates demand Japanese
mean“signal” or “visible record”
Materials and parts are the “parts” in manufacturing
Long setup times drive: (lo n g production runs, large slots, long lead time)
Customer’s needs are the “parts” in service industry
Pull - It has become a m atter of co u rse for cu sto m ers
Perfection - co m p lete elim in atio n o f all w aste
Ohno – p u t id eas in to p ractice systematically
TPS: Toyota Production System - searches for and eliminates waste
Pull system: m o v in g work where a workstation p u lls output
Push system: m o v in g work where output is p u sh ed
Setup reduction - Focused effo rts, P ro b lem so lv in g , F lex ib le eq u ip m en t
Minimizing Waste – Plant Loading
Minimizing Waste – F o cu sed F acto ry Networks
TPS – Respect for People
Modular design – clusters of parts treated
Highly capable production systems – quality is designed into t
SMED (single minute exchange of die)
Autonomation – automatic detection of defects during production. It referres
to jidoka
Work flexibility - Overall g o al of lean is to achieve . One p o ten tial obstacle is
bottlenecks, which occur when portions of the sy stem become overloaded. Takt time
– is the cycle time needed
Net time available p er d ay = 2*(480- 20*2- 30)=820minutes
contact method - identifies product defects by testing the
fixed-value method - alerts the operator
motion-step method - determines whether the prescribed steps
