Lean Introduction

1 www.lean-production.org
 What does Lean stand for?

Lean Production System

A roadmap to guide your Continuous
Improvement Process (CIP)

Waste

Plan, Do,
Check, Act
(PDCA)

Standardization

*) derived from the kaizen

standardization approach

2 www.lean-production.org
What does Lean stand for?

The Old Approach

Production
Customer Sales Development Purchasing Logistics

The Lean Approach – Design for Manufacturing

3 www.lean-production.org
 What does Lean stand for?
Lean supports a business from the Lean supports the entire supply
first customer idea to the final chain, from the supplier to the
delivery of the product. customer.

1. Suppliers
Inbound Milkrun,
Pull, … 2. Development,
Purchasing
3. Production, Standardization,
Packaging, …
SCM
Leveling,
Intralogistics, … 4. Customer
Product
Requirements, …

4 www.lean-production.org
 What does Lean stand for?
Lean supports a business from the Lean supports the entire supply
first customer idea to the final chain, from the supplier to the
delivery of the product. customer.

1. Suppliers
Inbound Milkrun,
Pull, … 2. Development,
Purchasing
3. Production, Standardization,

SCM Production Plant Packaging, …

Leveling, Let’s have a look inside the factory!

Intralogistics, … 4. Customer
Product
Requirements, …

5 www.lean-production.org
 The Product-Life-Cycle

100 % Line Capacity

80

Single Model Lines

Companies invest millions on production lines and
processes without utilizing their full (100 %) capacity
Average
40 Product (A)

0
Jan 15 Aug 15 Mrz 16 Okt 16 Mai 17

6 www.lean-production.org
 The Product-Life-Cycle

100 % Line Capacity

80

Single Model Lines

Companies invest millions on production lines and
processes without utilizing their full (100 %) capacity
Product (C)
Average Product (B)
40 Product (A)

0
Jan 15 Aug 15 Mrz 16 Okt 16 Mai 17

7 www.lean-production.org
 The Lean Production
House

8 www.lean-production.org
Lean Production System
The toolbox for all lean activities

Elimination of all Waste

Cost and Market Leadership
Lean Tools

Level 1 – Enabler Level 2 – Basics Level 3 – Experts Level 4 – Pro-Tools

Total
Obeyaka / Inbound Mizusumashi / Safety / Heijunka /
Standardization Lean Training Productive
Lean Layout Milkrun Tow Train Ergonomics Leveling
Maintenance

Takt Time / Operator-

One Piece Yamazumi / Mixed Model
5S Zero Buffer Process Supermarket
Lead Time Flow Line Balancing Line
Flexibility

3P /
Small-sized SMED 2-Box Jidoka /
Visualization Andon Pull / Kanban Design for
Packaging Changeover Principle Hanedashi
Manufacturing

Create a Vision
Lean Self-Assessment / Value-Stream-Design (VSD) *) derived from the “Toyota
Production House”

9 www.lean-production.org
 Lean Production System
(Examples)

SMED Changeover TPM Pull / Kanban

Internal and external preparation, e.g. 100 % equipment availability given Shortest lead time, e.g. in the fast-
in the Formula 1 for example in aviation food industry

Mizusumashi / Tow Train Jidoka / Hanedashi Standardization

Doctor-nurse interaction to feed Solve complex problems by finding Rules & routines as defined for
production lines simple solutions example in NASA space programs

10 www.lean-production.org
Lean Production System
The toolbox for all lean activities
Introduction to the
Seven Types of Waste
Elimination of all Waste
Cost and Market Leadership

Level 1 – Enabler Level 2 – Basics Level 3 – Experts Level 4 – Pro-Tools

Total
Obeyaka / Inbound Mizusumashi / Safety / Heijunka /
Standardization Lean Training Productive
Lean Layout Milkrun Tow Train Ergonomics Leveling
Maintenance

Takt Time / Operator-

One Piece Yamazumi / Mixed Model
5S Zero Buffer Process Supermarket
Lead Time Flow Line Balancing Line
Flexibility

3P /
Small-sized SMED 2-Box Jidoka /
Visualization Andon Pull / Kanban Design for
Packaging Changeover Principle Hanedashi
Manufacturing Introduction to the
Value Stream Design
Create a Vision
Lean Self-Assessment / Value-Stream-Design (VSD)

11 www.lean-production.org