Introduction lean

LeanManufacturingLeanChina2PrincipleofReasoningbyCustomerNeedWhatitPAYSInAdditionRawmaterialsandpackagingstrictlynecessaryMachinesandenergystrictlynecessaryValueAddedOperationsObligatorynormativecontrols,etc.FINISHEDPRODUCTMaterialsandPackaginglossesPoorqualityStockTransportationAuto-controlNon-productivehoursValueAddedTime.Proc.partsin30cm.Operations#pures.Normativecontrols.PhysiologicaltimesWHATitBUYSWhyweneedLEANMANUFACTURINGLeanChina3LMcentredondecreasinganddeleting7mainwastefamily3.Transportationorhandling1.Overproduction:2.Waitingtime6.Rework,Inspection4.Processoradministrative5.MicroMovement:Nonaddedmovement7.StorageManufacturemoremanufacturetooearlyTofinishthecycleforpartorfinishedgoodAllstepunnecessaryWhyweneedLEANMANUFACTURINGLeanChina4Pushthewasteoutoftheline,upstreamtowardthesuppliers.FirstPriorityImprovethelineImprovetheflowaroundthelineImprovetheglobalsupplychainPushthewasteupstreamandremoveitSecondPriorityThirdPriorityLeanChina5S/ERawMaterialIn-ProcessS/ERawmaterialIn-ProcessS/ERawMaterialIn-ProcessDABCHEFGIJS/EIn-ProcessRawmaterialFlowConflictDABCS/EFinishedProductIn-ProcessKLMLinesidestockand/orRawmaterialfromstoresareaInterruptedFlowStockinvestmentX2ABCDKLIJEFGHMFrequentTransportImportantMovementsIncreasedStockIdentifiedImprovement:-Unnecessarymovement-Obstaclesfortheflow-Passagetimetoolong–In-Process-Operatortasksnotlinked-….ButstockabsorbsproblemsFokusonthevalue-addedtasksfortheoperator–eliminatethereplenishmentactivitiesLeanChina6S/ERawMaterialIn-ProcessS/ERawMaterialIn-ProcessS/ERawMaterialIn-ProcessDABCHEFGIJS/EIn-ProcessRawmaterialDABCS/EFinishedProductsIn-ProcessKLMLinesidestockand/orRawmaterialfromstoresareaABCDKLIJEFGHMS/ES/ES/ES/ES/EEFGS/ES/EDHCBAJIKMLFinishedProductsUsingLeanManufacturingConceptsDirectreplenishmentofoperationswiththenecessaryfrequencyLeanChina7S/ES/ES/ES/ES/EEFGS/ES/EDHCBAJIKMLFinishedproducts-Theflowisveryquick-Themovementsareminimised-Theworkersconcentrateonthevalue-addedtasks-L'équipeauncontratd'objectifàl'heureThestockandtheIn-Processisreducedtotheminimum.Conceptofone-piece-flowReplenishmentstrategiesarere-visitedLeanChina8Supplyparts:OnlyonecircuitorganizedABCDKLIJEFGHMLinePartsstockedinonlyoneplace.ex:FromwarehousetotheworkstationProducts,WastepartsMaterialHandlingSolution:TheWATERSPIDERS/ES/ES/ES/ES/EEFGS/ES/EDHCBAJIKMLProductsLeanChina9WhyweneedLEANMANUFACTURINGBenefits-IncreaseIndustrialEfficiency-Reducetimetakenbyprocess(PLT)-Reducewaste(7wastes)-Reducenon-value-addedactivities(Redtime)-…Fivedrives-Cost,Quality,Delivery,SafetyandMoralMethodology-MTM-KANBANsystem(JIT)-5S&visualcontrolsystem-multi-skillworking(laborandworkstation)-Ushapedform-Waterspider-…SummaryA92A939495LeanChina10OriginsAconceptstemmingfromtechniquesimplementedwhentheTPSTOYOTAPRODUCTIONSYSTEMwasdrawnup(1945–1975)TPSwasdevelopedandconceptualisedbyMessrs.TAIICHIOHNO(Vice-PresidentTOYOTA)andSHIGEOSHINGO(FoundingConsultantofIMI(InstituteofManagementImprovement).TPSBuildingtheTPS19451975LeanManagementConcept:-leanmanufacturing-leanofficeWhat’sLEANMANUFACTURINGLeanChina11Origins(follow-up)TPSisasystembywhichthemanufacturingprocessispermanentlyoptimised(associating)theproductionstaff.Thetargetistobeexcellentincostumersatisfaction.1.1Technical”Bases1.2SocialBasesProductionstaff'semploymentguaranteedforlife.Onlyonetradeunioninthecompany.Decisionstakenonagroupbasis1.3EconomicBasesPerformancemodelledonthebasisofthecustomerbeingsatisfiedontwocounts:-Leadtime-PriceSalesprice=costs+profitWhat’sLEANMANUFACTURINGLeanChina12Origins(follow-up)1.4ProductionBasesAimatsatisfyingthedemandbysingle-unitproduction.Thetransformationsoftheproductionflowresultingfromthepostulateeliminatetheneedtomodelthedemandandsimplifyprogrammingtoasubstantialdegree.Simplifyalltheoperationsandeliminatetransport,storageandhandling.Mechaniseeverythingthatdoesbelongtoamentalcontributionbytheoperators.What’sLEANMANUFACTURINGLeanChina132.1FieldsofApplication:WORKORGANISATIONTheindustrialflowissplitbetween:operationsProcessoperationsactionscarriedoutonthematerialbymachinesandoperatorsOOPOOP…..INTEROPERATIONStorage-Controls-Delays-Transport/HandlingGeneralprinciplesWhat’sLEANMANUFACTURINGLeanChina14TheLeanManufacturingprogrammeiscentredonEliminatingwaste,delays,handling,controls,Reviewinglinearchitecture(flow,installations)ReviewingsupplychainOptimisingOperationsintheProcess2.2FieldofApplication:WORKORGANISATIONGeneralprinciples(Follow-up)What’sLEANMANUFACTURINGLeanChina15Aimatreducingtheproductioncycleandenable2.3FieldofApplication:WORKPROGRAMMINGAdaptcapacitytothecustomer'sinstantaneousdemandResultsinresolvingtheconflictObtaintheresourcesPieceworkProductionProd.BatchesSaturationresourcesOptimisationofdirectcostsdepreciationtowardszeroinflatedResultsinfoundingasocialagreementFixtureMobileGeneralprinciples(Follow-up)What’sLEANMANUFACTURINGLeanChina162.4ManagementRulestheycomefromthetriangleReductioninconflictsofinterestManagement/OperatorsRespectingthefactoryfloorstaffWorkingconditionsE