Dr.

Rupy Sawhney

Module

Fundamentals of Lean Enterprise

Systems
Designing & Modeling of Lean
Systems
Reliability of Lean Systems
Analysis of Lean Systems
Project-oriented week presentations

Week

1
2&3
3
4
5

Monday
Tuesday
Wednesday
Thursday
June
30 July
1
2
Fundamentals of Lean Enterprise Systems (Intro to phylosophy and tools)
(10-11:30)
7
Opening Ceremony
Foundry 8-12
Orientation
I-house 1:30 - 3:30

(10-11:30)

(10-11:30)

(10-11:30)

Friday
3

Saturday
4

Early Check-In
(extra cost)

Sunday
5

Check-in
UT Transportation
provided
from TYS Airport

6
Late Check-in
UT Transportation
provided
from TYS Airport

Dr. Rupy
Sawhney

MS. Isaac
Mitchell

MS.
Bharadwaj
Venkatesan

MS. Enrique
Macias de
Anda

Experienced consultants from CIS

Misty DePriest

You must've heard an old sea story about a ship's Captain who inspected his
sailors, and afterward told the first mate that his men smelled bad.
The Captain suggested perhaps it would help if the sailors would change
underwear occasionally. The first mate responded, "Aye, aye sir, I'll see to it
immediately!"
The first mate went straight to the sailors berth deck and announced, "The
Captain thinks you guys smell bad and wants you to change your underwear."
He continued, "Pittman, you change with Jones, McCarthy, you change with
Witkowski,
and
Brown, you change with Schultz."
THE MORAL OF THE STORY:
Someone may come along and promise
"Change",
but don't count on things smelling any better.

What Does History Teach Us ?

Out of business

Panhard
&
Levassor

Out of business

Henry Ford
& GMs
Alfred Sloan

Toyotas
Eiji Toyoda
&Taiichi
Ohno

Niche
Markets (Aston)

Past Craft Production

WWI Mass Production 1960 Lean Production

Now

MARKET COMPETITION
TODAY

PRICE OF MP3 Players

Freivalds, Andris (2009), Niebels Methods, Standards, and Work Design

12th Ed. McGraw Hill, New York, U.S.A.

COST OF OUR PRODUCT

What if

1. INCREASE PRICE
AFTER
CRISIS

PRICE OF MP3 Players

After increase in price, the possible effects are:

1. Market share loss
2. Sales reduction
3. Profit reduction

2. REDUCE PROFIT

3. REDUCE WASTE

Ben-Hur (1959), http://theworldofjot29.blogspot.com/2012/09/ovp-ben-hur-1959.html

http://www.allempires.com/Forum/forum_posts.asp?TID=30714

Values

Your Leadership

Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization

Principles

Culture

Values

Your Leadership

Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization

Principles

Culture

Is This Value?

Current Competitive Dimensions:

Value = Quality + Price + Delivery

Value Manufacturing Competitive Dimensions :

Value = Quality + Price + Service + Innovation

What Are The Dimensions On Which Lean

Allows You To Compete?
Cost
Quality
Delivery
Others?

Values

Your Leadership

Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization

Principles

Culture

Your Desired Culture is Defined

By What?

Values

Your Leadership

Development and
enhancement
of a culture
that provides the
greatest
probability of achieving
the
values of an
organization

Principles

Culture

Lean
Lean focuses on eliminating nonvalue added steps and activities in
a process.
Lean makes sure we are working
on the right activities.
Lean establishes the value flow as
pulled by the customer.

Source: Air Academy Associates

Six Sigma

Six Sigma focuses on reducing

variation from the remaining valueadded steps.
Six Sigma makes sure we are doing
the right things right the very first time.
Six Sigma makes the value flow
smoothly without interruption.

 A business system that connects

and empowers employees to
improve the value of our products
and services to customers by
reducing waste and producing what
is required.

Specify value in the eyes of the

Identify the value stream and

Make

at the pull of the customer.

Involve, align and empower

knowledge in pursuit of
perfection

 Waiting
Conveyance
Inventory
Motion
Processing
Employee creativity
Poor quality
Scrap

Rework
Correction
Overproduction
100% inspection
Overtime
Added operations
Increase of variance

 Four Pillars
Appropriate Systems
Employees
Capability
Continuous Improvements
Shop Floor Guidelines

IN COMMON SENSE TERMS

LEAN TRAINING

QUESTIONS