Hence, the method is well suited for simulations, but less suited for reals hop floors. Establish, in advance, exactly what constitutes successful completion of an action item. Such policies may include: We provided product in days.
Andon - a system of flashing lights used to indicate production status in one or more work centers; the number of lights and their possible colors can vary, even by work center within a plant; however, the traditional colors and their meanings are: Opposite of Low Mix High Volume.
Our customers loved the quick response, and soon got dependent on it. Usually it includes the right quality, right quantity, right material type, right place, right time, right source, right price, right type of transport, right contract. For most other products, given enough time and money, any bottleneck can be overcome.
Philosophy of developing people. Design of experiments to maximize the understanding of the system with the minimum number of experiments needed using statistical tools. Rephrased by Shigeo Shingo in the politically more correct mistake proofing poka yoke.
The ability to build mass-customized and standard products on-demand is the payoff for lean production programs. Note that much setup is designed into the product and process.
C Maximize the amount of dimensional variation done with CNC C Standardize raw workpieces and fixturing to eliminate setup C Quick and automatic program change C Standard cutting tools within tool changing capability C Automatic material feed and eject optional C For sheet metal, nesting optimization can evolve over time C For unusual and low-volume parts, using a CNC machine to "hog out" parts may lower total cost if it avoids a stocking a high variety of low-volume parts or b complications and delays in the supply chain for low-volume castings or moldings.
Built-in quality means to stop at every doubtful part and to train yourself and others not to pass on defective work, not to do defective work and not to accept defective work by stopping the process and reacting immediately whenever things go wrong.
Challenge the validity of all perceived bottlenecks. Everyone and everything must support the chosen strategy.
We had a client that was experiencing great difficulty staffing a second shift. Check Points and Control Points — used in measuring the progress of improvement-related activities between different managerial levels. Provide some discretionary funding, when appropriate, to allow the team to try low-cost ideas without going through an approval cycle.
Critical Equipment Spare Parts: In flow manufacturing, parts may be manually handed to the next station, which may be very close, thus eliminating the need for mechanized conveyance or fork lifts, whose aisles may occupy as much space as the production line.
C If takt time does not equal station capacities, but does not vary with products: These problems are not found in a meeting in a conference room.
Order entry must have, and use, rough cut capacity control. Just as you would not attempt to drive a nail with a screwdriver, each of these tools has an appropriate time and place for its use. They also coordinate improvements activities. If this should fail, in the most spectacular way, can we recover.
In Geoffrey Mika in his book, "Kaizen Event Implementation Manual" added three more forms of waste that are now universally accepted; The waste associated with working to the wrong metrics or no metrics, the waste associated with not utilizing a complete worker by not allowing them to contribute ideas and suggestions and be part of Participative Management, and lastly the waste attributable to improper use of computers; not having the proper software, training on use and time spent surfing, playing games or just wasting time.
We are uncovering better ways of developing software by doing it and helping others do it. See also the Fixed Repeating Schedule for an almost identical approach.
Another difference is that Lean focuses on the production and Agile on the product. Maintenance – activities that are directed to maintaining current technological, managerial, and operating standards. Mixed-model production – capability to produce a variety of models, that in fact differ in labor and material content, on the same production line; allows for efficient utilization of resources while providing rapid response to marketplace demands.
Lean Manufacturing & Operations. Lean is about eliminating waste. It consists of a set of attitudes, philosophies, principles, analysis tools and specific work structures that form a production system.
In my last post, I started a series on the conventional supply chain strategies and why they are inadequate to help firms trying to design their supply thesanfranista.com continues the series with the focus on lean as a supply chain strategy.
Lean primarily refers to elimination of waste and is the basic philosophy that originated as part of Toyota Production Systems, with its emphasis on the. Lean Manufacturing is not especially new. It derives from the Toyota Production System or Just In Time Production, Henry Ford and other predecessors.
The lineage of Lean manufacturing and Just In Time (JIT) Production goes back to Eli Whitney and the concept of interchangeable parts. Transforming Culture and Capabilities to Execute Business Strategy: The Agile Way to Business Strategy Success.
The Lean Startup isn't just about how to create a more successful entrepreneurial business it's about what we can learn from those businesses to improve virtually everything we do. I imagine Lean Startup principles applied to government programs, to healthcare, and to solving the world's great problems.Lean production strategy