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P r o d . A d m in . A re a M g m t.
H ig h Q u a lit y
M a n * S u p p o r t s s e n io r
M a n a g e m e n t M a ch m a n a g e r s g o a ls ,
d e v e lo p e d t o M a t l m is s io n s , a n d
s u p p o rt d ir e c t iv e s
o p e r a t io n
im p r o v e m e n t JIT M in .
I n p u t
P ro c e s s M a x .
O u tp u t
J id o k a * P r a c t ic e o p s
m g m t . O n a d a ily
b a s is
M e th o d * D e v e lo p y o u r s t a f f
e v e ry d a y
* K a iz a n e y e lo o k s
f o r im p r o v e m e n t
M in im u m L e a d T im e
e v e ry w h e re
O p e r a t io n s
d e v e lo p m e n t S t a n d a r d iz e d W o rk
g ro u p to
s u p p o rt sh o p
f lo o r
O p e r a t io n s M a n a g e m e n t C o n d it io n s
S h o p F lo o r * M u s t b e o p e n
* F o rm e r
C o lla b o r a t io n to s u p p o rt a n d
m a n a g e rs fro m
c o lla b o r a t io n
s h o p f lo o r
O p e r a t io n r a t e * R e c o g n iz e
* C o n s u lt a n t s
I n d ic a t o r s P r o b le m S o lv in g N e e d fu tu re n e e d s
f o r s e r io u s
K a iz a n O p p o r t u n it ie s
o p e r a t io n s
C o lla b o r a t io n
p r o b le m s
O D G O p e ra to rs
* S im u la t io n s P ro je c t A c t iv it ie s
* E d u c a t io n S e t T a rg e ts
* L iv e G r a s p S it u a t io n
Im p ro v e m e n t S e t S t r a t e g ie s
p ro je c ts P D C A
* D e v e lo p s t a f f
M M
A M
G L
E n a b le r s
* C a p a b le s t a f f
* O D G P ro j. E x p e r. T L
* R e f e r e n c e M a t l.
* W illin g / o p e n I m p ro v e d O p e r a t io n s
The Goal
Lower costs
Higher quality
More flexibility
Dr. C. W. Richards 1/12/99
The Strategy
Cost
CostReduction
ReductionIsIsthe
theGoal
Goal
Alllactivitiiteisesmusttsupportt
the
thegoallofofshortening
ingthe
thetime
timeitittakes
takestotoconvertt
Al activ mus suppor goa shorten conver
cus tomer orders into deliverie s. Toyota Motor Corpora tion, 1992
customer orders into deliveries. Toyota Motor Corporation, 1992
Design The
Develop A Manufacturing Establish Flow Establish Pull Strive For
Lean Strategy System Within Cells Between Cells Perfection
Create a sense of urgency Identify the Form
Form cells
cells based
based Design an Institute kaizen
customer base on
on takt
takt time
time information & institutionalize
Throughout the enterprise,
and product system to produce 5Ss throughout
sell lean/TPS as the solution Define
Define standard
standard
range only the products organization
work
work content for
content for
Hire a sensei & retain required by the
Identify takt time each
each operation
operation to
to Transfer
design talent downstream cells
& its range be < takt time
be < takt time ownership of all
Establish targets Incorporate takt processes to
Apply
Apply axiomatic Separate
Separate worker
worker
Resolve how to maintain design to create time to drive work force
from machine
from machine
mutual trust while reducing the basic factory flows
(jidoka)
(jidoka) Push lean down
people system Institute leveled to suppliers
Develop
Develop quick
quick
Give preliminary thought to production
Eliminate non- setups & standard
setups & standard Integrate product
supplier issues (heijunka)
essential WIP
WIP (SMED)
(SMED) development
Consider the competitive infrastructure Use visual control
Standardize
Standardize Reduce people at
environment and layers above systems
operations
operations all levels in the
the factory floor Implement total organization
productive
maintenance
Manufacturing
as a
Competitive
Weapon
Dr. C. W. Richards 1/12/99
LEAN PRINCIPLES
VALUE
VALUE STREAM
FLOW
PULL
PERFECTION
- LEAN THINKING
by JAMES P. WOMACK
and DANIEL T. JONES
LEAN PRINCIPLES
VALUE
VALUE IS DEFINED BY THE
CUSTOMER AND EXPRESSED IN
TERMS OF A SPECIFIC PRODUCT
WHICH MEETS THE CUSTOMERS
NEEDS AT A SPECIFIC PRICE AT
A SPECIFIC TIME.
LEAN PRINCIPLES
VALUE STREAM
THE VALUE STREAM IS THE SET OF ALL
THE SPECIFIC ACTIONS REQUIRED TO
BRING A SPECIFIC PRODUCT THROUGH
THE THREE CRITICAL MANAGEMENT
TASKS OF ANY BUSINESS: PROBLEM-
SOLVING (RUNNING FROM CONCEPT TO
PRODUCTION LAUNCH), INFORMATION
MANAGEMENT (FROM ORDER-TAKING TO
DELIVERY), AND PHYSICAL
TRANSFORMATION (FROM RAW MATERIALS
TO FINISHED PRODUCTS IN THE HANDS
OF THE CUSTOMER).
VALUE STREAM ANALYSIS
IDENTIFY THREE TYPES OF ACTIONS:
More info? Most of these terms are well defined and illustrated in Lean Thinking, by
James P. Womack and Daniel T. Jones (New York: Simon & Schuster, 1996)