GBE-KPO-2-001-00-Lean-Basics-1

1GBE-KPO-2-001-00LeanBasics1Rev.04Design.Build.Ship.Service.LeanTrainingLeanBasics1LeanBasics1BusinessExcellence2GBE-KPO-2-001-00LeanBasics1Rev.04APPROVALSNAMETITLEDEPTNAMEDATEGaneshSManiamDirectorGlobalBusinessExcellenceDecember11,2008REVISIONHISTORYREVISIONDESCRIPTIONOFCHANGEORIGINATORRELEASEDATE04DocumentformattedasperDMSpolicyChuahKharYeeDecember11,2008ThisdocumentisproprietaryandconfidentialpropertyofFlextronics.DocumentTitle:LeanBasics1Document#GBE-KPO-2-001-00Organization:GlobalBusinessExcellenceRevision:04DocumentOwner:ChuahKharYeeEffectiveDate:December11,20083GBE-KPO-2-001-00LeanBasics1Rev.04ContentsSlide(s)TableofContentsƒOverview&Scope3ƒObjectives4ƒABriefHistoryofLean6ƒTheFlextronicsLeanEnterprise(FLE)13ƒWasteElimination16ƒValueStreamMapping(VSM)29ƒ5S&VisualManagement37ƒSuperMarket554GBE-KPO-2-001-00LeanBasics1Rev.04Overview&ScopeƒLeanManufacturingisagenericprocessmanagementphilosophyderivedmostlyfromtheToyotaProductionSystem(TPS)butalsofromothersources.Itisrenownedforitsfocusonreductionof‘SevenWastes'inordertoimproveoverallcustomervalue.*ƒToyota'sachievementmadeLeanahottopicinmanagementscienceinthefirstdecadeofthe21stcentury.ƒLeanManufacturingcanbedefinedas:Asystematicapproachtoidentifyingandeliminatingwaste(non-value-addedactivities)throughcontinuousimprovementbyflowingtheproductatthepullofthecustomerinpursuitofperfection.InfoSource:*5GBE-KPO-2-001-00LeanBasics1Rev.04ObjectivesƒIntroduceFlextronicsLeanEnterprise(FLE)anditselements•WasteElimination•ValueStreamMapping(VSM)•5S&VisualManagement•Supermarket6GBE-KPO-2-001-00LeanBasics1Rev.0498%ofOrganisationsthatengagewithLean,Fail!!WHY???LeanisHARD!!!Excerptsfromthebook“LeanMachines”LeanThinkingIt’sapeopleissue.That’swhyit’ssohard.Gettingpeopletochange–todothingsdifferentlythantheyhavedonethem–isreally,reallyhard.¾ArtByrne,CEOWiremoldIfacompanyisreallymaniacalaboutLeanittakestwotothreeyearstogofromkindergartentofirstgrade.That’showtoughitis.¾MarkDeLuzio,architectoftheDanaherBusinessSystem,DanaherWhatExecutives(Really)NeedtoKnow7GBE-KPO-2-001-00LeanBasics1Rev.04ABriefHistoryofLeanLeanHistoryTimelineTheOriginsofLeanManufacturing8GBE-KPO-2-001-00LeanBasics1Rev.04FatherofManagementFatherofMotion-TimeStudyFatherofAssemblyLineConceptIndustryQualityTransformationBirthofTPS/LeanConcepts“TheMachineThatChangedTheWorld”“LeanThinking”InfoSource:’rootintheToyotaProductionSystem(TPS).SeveralindividualsatToyotawereinstrumentalindevelopingandsystematizingTPS.Amongthemostimportantwere:SakichiToyoda(1867~1930)•Japan’s“KingofInventors.”•HisconceptofJidoka(autonomation)isoneofthefoundationalprinciplesofTPS.•FirstappliedtoToyodaPowerLoomequippedwithanewweft-breakageautomaticstoppingdevice(developedin1896).•World'sfirstautomaticloomwithanon-stopshuttle-changemotion,theType-GToyodaAutomaticLoom(developedin1924).•FoundedToyotaMotorCo.in1937.Formoreinfo::(1894~1952)•Sakichi’sson.•TheTPShasevolvedthroughmayyearsoftrialanderrortoimproveefficiencybasedontheJust–in–Time(JIT)conceptsdevelopedbyKiichiroToyoda,thefounder(andsecondpresident)ofToyotaMotorCorporation.•InheritedSakichiToyodaphilosophy,setouttorealizehisbeliefthat“theidealconditionsformakingthingsarecreatedwhenmachine,facilitiesandpeopleworktogethertoaddvaluewithoutgeneratinganywaste“.•Conceivedmethodologiesandtechniquesforeliminatingwastebetweenoperations,betweenlines,betweenprocesses.TheresultwasthesocalledJITmethod.•Drawingonhisexperienceofintroducingaflowproductionmethodusingachainconveyorintotheassemblylineofatextileplant(completedin1927)withamonthlyproductioncapacityof300units.•IntroducedthismethodintothebodyproductionlineatToyotaMotorCo.,Ltd.'sKoromoPlant(presentdayHonshaPlant),completedin1938.•HestudiedFord’sproductionsystemandadaptedittothesmaller,morediverseJapanesemarket.Formoreinfo::(1913~)•ByensuringthoroughimplementationofJidokaandtheJust-in-Timemethod,EijiToyodaincreasedworkers'productivityinaddingvalueandrealizedtheToyotaProductionSystem,whichenabledToyotatocompetehead-onwithcompaniesinEuropeandtheU.S.Formoreinfo:(1912~1990)•WithstrongbackingfromEijiToyoda,TaiichiOhnohelpedestablishtheToyotaProductionSystem,andbuiltthefoundationfortheToyotaspiritofmakingthingsby,forexample,creatingthebasicframeworkfortheJust-in-Timemethod.•Knownasthe“ArchitectofTPS.”•SystematizedJidoka,JIT,standardizedworkandkaizenintowhatwenowknowasTPS.•Fatherofthesupermarketsystemofinve