ZDC - LMC Presentation

ZERO DEFECT CONSULTANTS Lean Manufacturing
Lean Manufacturing Implementation and its Roadmap
By. Dr. S M Jagadish

Zero Defect Consultants
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Presentation Contents
Consultants Profile ( Dr. S M Jagadish ) Company Profile ( Zero Defect Consultants ) Experience of cluster Cluster and its problems General Approach for Lean Mfg Implementation General Road map of lean Mfg implementation Phase-wise Deliverables / Performance indicators Experience in Lean Manufacturing Projects Case Study Lean Manufacturing Introduction Suggested Lean Implementation Approach Suggested Lean Techniques and Deliverables 2
Consultants Profile
Name : Dr. S M Jagadish Accademic Qualification : Doctorate in Management Studies - Total Quality Management Master in Business Administration - Marketing Bachelor of Engineering Professional Qualification : Lead Auditor for ISO9001, ISO14001, OHSAS 18001 NABET Approved Consultant Two Years Further Education Program (FEP) on Tool and Die Making Design and Manufacture 3 - Mechanical
Consultants Profile Contd..

Technical Membership : National Institute for Quality and Reliability ( NIQR) Consultancy Development Centre (CDC) Quality Circle Forum of india (QCFI) Training Experience : Approved Faculty for 1. Underwriters Laboratory ( UL) india for DOE, ISO/IEC17025 2. Doha Training Centre ( QATAR) 3. Electronic Test and Development Centre (ETDC) for ISO/IEC 17025 ( NABL) internal auditors training 4. Faculty for BITS Pilani -TQM Topics in M S -Quality Management 4
Consultants Profile Contd..

Total Experience : 16 years Industrial Experience : In SSI unit ( Maruthi Metals & Plastics Pvt Ltd ) at Veerasandra Medium Size Company ( NTTF Industries Limited) at Peenya Consultancy Experience : Around 12 years of Consultancy Experience having visited more than 700 plus industry for providing consultation and training Lean Experience : I have implemented many lean tools in many organization however I have implemented Lean Manufacturing as a project in 3 Companies. 1 Small Scale industry and 2 Medium size industry 5
Company Profile - Zero Defect Consultants

Background Zero Defect Consultants was formed in the year 2000 with the objective of consulting the organization to implement Zero Defect Systems Zero Defect Consultants has offices at multiple locations in southern and Western India with head office at Bangalore Has 20 Full time Consultants across all Branches Has more than 550 satisfied customers Member of NABET and Consultancy Development Centre, which is an Autonomous Institution promoted by DSIR, Ministry of Science & Technologies 6 Management
Company Profile - Zero Defect Consultants Contd.

Services offered Training & Consulting Services on ISO 9001, ISO/TS 16949, ISO 14001, HACCP, OSHAS 18001, ISO 27001, ISO 20000, ISO 13485, ISO/IEC 17025, AS9100, ISO 22000, FIDI FIAM, TPM, Six Sigma, Lean Manufacturing, etc.. After Certification services such as Post ISO9001, Post TS16949 etc. for improvement or maintenance Turnkey Projects on Continuous Improvement, Quality Improvements, Kaizen implementation, 5S Implementation, Statistical Process Control, Measurement System Analysis, DOE implementation, TIAN Suggestion Scheme, etc. Training on various Quality related topics 7
Company Profile - Zero Defect Consultants Contd.

Some of our Major Customers are Harita Seating Systems Ltd Sundaram Plastics ltd. Solectron Centum Ltd. Indo US Mim Tec Pvt. Ltd. Asian Bearings Ltd. Aditya Auto Products Pvt. Ltd. Addon Engineering Pvt. Ltd. John Fowler India Ltd Haw let Packard ( H P) Titan Industries Ltd. Senapathy Whiteley Pvt. Ltd. Indian Seamless Steel Ltd. ITC Ltd. & CIGFIL Ltd. Marbu Contacting WLL - Qatar Steel Authority of India Ltd [SAIL] Aisin NTTF Pvt. Ltd. Avasarala Technologies Pvt. Ltd. Indian Oil Skytanking Ltd. NTTF industries Ltd. Sartorious India Pvt. Ltd. Bill Forge Pvt. Ltd. Bajaj Electricals Limited Suparjith Engineering Ltd Mungi Group Reliance Industries Ltd. Palanpur Engineering Pvt Ltd Echjay Industries Ltd. Witzemann India Pvt. Ltd. Wipro Ltd. Hindustan Coca-Cola Beverages Ltd. 8
Experience of Cluster Approach

Zero Defect Consultants was first to implement the cluster approach in consultancy during the year 2001 for implementing ISO9001:2000 with more than 20 clients put under initial list and later finalized with 8 clients with the help of Hosur Small and Tiny Industries Association (HOSTIA). We have successfully completed the Deliverables within the agreed time line with the help of the organizations and Certifications body. With this success in cluster program we deployed the same to the suppliers of our that point major customer like Haritha Seating Systems Limited , Sundaram Plastics Limited at Hosur , Addon Enginering Pvt Limited at Bangalore Etc. 9
Experience of Cluster Approach

We have been awarded as a consultant to implement Lean Manufacturing at BMTMLA cluster ( Machine Tool Cluster) by NPC. We have 9 Companies with Varity of Products and of different verticals. Organization consist of Industries who form SPM using Mechanical, Electronics and Software products.
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Cluster and its Problem

Cluster is group of industry working on a common platform coordinated by a common body for the upliftment of all the members of the cluster. Some of the common problems what we have faced during implementation of cluster approaches are Present status of all the members will not be same , when standard approaches are adopted we will not be able to deploy effectively in all the members hence we need to have customized approach for each member. If Top Management Commitment and priorities are not there, then team commitment will be low in that organization leading to poor response hence prior commitment on involvement to be obtained. 11
Cluster and its Problem Contd..

If one members does not participate effectively, or talks negatively, then team will have difference of opinion leading to failure in the implementation. Change of person in any member industry in between will be like restarting the whole project, hence task force needs to be identified in each cluster members and for project deployment. Conflicts will arise within the members on the support provided by the consultants. Generally consultants works where they can show results where by members with poor response will not be attended/focused leading to failure in implementation targets hence effective reviews to be carriedout 12

Efforts required depends on competency of employees within the cluster members, for same efforts there could be large variation in end results. Hence Customized deliverables to be decided for each member. Resources addition and requirements may vary from member to member based on the present status, so ROI may vary from member to member. Hence Priorities to fixed by the each member depending on their requirements. Resistance to change will vary from member to member so their could be variation in effective project implementation hence communication on the need of change to be effectively carried out. 13

Their could be failure if there is no allocation of budget for effective implementation of this project hence proper Financial Planning to be carried out with budget allocation. Since the project calls for cultural change, Top managements commitment for this change is a must hence long term vision or Missions to be set by the members Sustenance is a real challenge, we need to develop the basic habits by continuingly practicing the changed practices hence desire for change needs to emphasized before start of the project. 14
General Approach for Lean Mfg Implementation

Conduct gap analysis in each individual unit. Asses the Lean Manufacturing techniques that needs to be implemented in each unit Develop implementation Road Map with Time line. Providing Awareness and other training to the employees for each LM technique Implementation covering process documentation, review, pilot, finalize, train and company wide implementation Analyzing the outcome of the implementation Establishing continuous monitoring system Conduct continual monitoring Convene Review Meetings Reporting to the concerned with the areas requiring actions to all concerned in all formats such as report, videos etc. Prepare Case Study and Closing report for each unit 15
General Road Map for Lean Mfg Implementation

Phase No. 1 Phases Planning & Introduction Steps for Lean Initiation Announcement through MD Introduction Campaign Project Organization Agreeing Targets Preparation introduction plan 2 Deployment Training of Value Stream Mapping Structured Deployment Monitoring System Establishment Schedule Planned 1st Week of First Month 1st Week of First Month 2nd Week of First Month 3rd Week of First Month 4th Week of First Month 1st Week of Second Month 2nd Week of Second Month Continuous 4th Week of Second Month
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Phase No. 3 Phases Steps for Lean Initiation Schedule Planned 1st Week and second Week of Third Month 3rd and 4th Week of Third Month Continuous 1st & 2nd Week of Fourth Month 3rd & 4th Week of Fourth Month 1st Week of Fifth Month 2nd Week of Fifth Month Continuous 4th Week of Fifth Month 1st Week of Sixth Month 2nd Week of Sixth Month Continuous 4th Week of Sixth Month 1st & 2nd Week of Seventh Month Deployment Training of 5S & Visual Management Structured Deployment Monitoring System Establishment Review 4 Deployment of Kaizen Training Structured Deployment Monitoring System Establishment 5 Deployment of TPM Training Structured Deployment Monitoring System Establishment Review
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Phase No. 6 Phases Deployment of One Piece Flow Steps for Lean Initiation Training Structured Deployment Monitoring System Establishment 7 Deployment of SMED Training Structured Deployment Monitoring System Establishment Schedule Planned 3rd Week of Seventh Month 4th Week of Seventh Month Continuous 2nd Week of Eighth Month 3rd Week of Eighth Month 4th Week of Eighth Month Continuous 2nd Week of Ninth Month
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Phase No. 8 Phases Deployment of Kanban Structured Deployment Monitoring System Establishment 4th Week of Ninth Month Continuous 3rd Week of Tenth Month Weekly Review of Status from 4th Week of Tenth Month to 4th Week of 12th Month Continuous Weekly Monitoring for One year Monitoring as per agreed target dates during weekly review Steps for Lean Initiation Training Schedule Planned 3rd Week of Ninth Month
Review 9 10 Monitoring Management Review
Corrective Actions / Review Gaps and Pending Continual Improvements Actions
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Phase-wise Deliverables / Performance indicators

Phase as per Road Map Phase 1: Planning and Introduction Period as per Road Map 1st week of 1st month to 4th week of 1st month Lean Mfg Technique Quantitative Deliverables -----------------------------------Qualitative Deliverables Document Present Status Agreeing Targets Obtaining Management Commitment Preparing Lean Introduction plan Training Structured Deployment Change of Method System Establishment
Phase 2 : Deployment of Value Stream Mapping
1st week of 2nd Value Stream Mapping month to 4th week of 2nd month
Improved Takt Time Improved Productivity
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Phase as per Road Map Phase 3 : Deployment of 5S and Visual Management Period as per Road Map Lean Mfg Technique Quantitative Deliverables Reduced Lost Time due to Accidents Improved Productivity Reduced Rejection Reduced Rework Reduced Cost Improved Delivery Improved Employee Participation Qualitative Deliverables Training Structured Deployment Change of Culture System Establishment Improved House Keeping Improved Visual Management Improved Morale 1st week of 3rd 5S & Visual month to 2nd Management week of 4th month
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Phase as per Road Map Phase 4 : Deployment of Kaizen Period as per Lean Mfg Road Map Technique 1st week of 5th Kaizen month to 4th week of 5th month Quantitative Deliverables Improved Employee Participation Improved Productivity Reduced Rejection Reduced Rework Reduced Cost Improved Delivery Reduced Lost Time due to Accidents Qualitative Deliverables Training Structured Deployment Change of Culture System Establishment Improved Morale
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Phase as per Road Map Phase 5 : Deployment of TPM Period as per Lean Mfg Road Map Technique 1st week of 6th TPM month to 4th week of 6th month Quantitative Deliverables Improved OEE Qualitative Deliverables Training Structured Deployment Change of Culture System Establishment Improved Morale
Reduced Un Planned Down Time Improved Productivity Reduced Cost Improved Delivery Reduced Lost Time due to Accidents Reduced Rejection Reduced Rework Improved Employee Participation -
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Phase as per Road Map Phase 6 : Deployment of Manufacturing Cells/ One Piece Flow Phase 7 : Deployment of SMED Period as per Road Map 3rd week of 7th month to 2nd week of 8th month Lean Mfg Technique Manufacturing Cells/ One Piece Flow Quantitative Deliverables Improved Cycle time Reduced Inventory Reduced Rework Qualitative Deliverables Training Structured Deployment System Establishment
3rd week of 8th month to 2nd week of 9th month
Setup Reduction (SMED) -
Reduced Set up Time Improved Cycle Time Improved Productivity
Training Structured Deployment System Establishment
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Phase as per Road Map Phase 8 : Deployment of Kanban Period as per Lean Mfg Road Map Technique 3rd week of Kanban 9th month to 3rd week of 10th month Quantitative Deliverables Reduced Inventory Reduced Customer Line Stoppage Reduced Customer Delivery Complaints Reduced Premium Freight Improved Customer Delivery Improved Inventory turnover ratio Reduced Inventory Qualitative Deliverables Training Structured Deployment System Establishment Effective Inventory Management
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Phase as per Road Map Phase 9 Monitoring Period as per Road Map Lean Mfg Technique Quantitative Deliverables ------------------------Qualitative Deliverables Status Review
Phase 10 Corrective Action / Continual Improvements ----------------------------
Status Review
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Experience in Lean Mfg Consultancy Projects Case study

Company Introduction Type of Industry : Small Scale Industry Industry Location : Peenya Industrial Area;Bangalore Company Name : Maruthi Automats Type of Company : Partnership firm No. of Employees : 14 Nos. Type of Machines : Automats, Drilling, Facing, No. of Machines : 5 automats, 1 Drilling, 1 Facing, Type of Products : Turned components No of Products : 20 Consultancy for : Lean Manufacturing Consultancy Period : One Year
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Case study Contd.. Summary of Improvements Quantitative Data

CATEGORY Production per Day Manpower Reduction Manufacturing Lead Time Tool Change Over Rejection Total Employee Involvement Customers Complaints Multi- Skilling One-up One Down House Keeping PRE - LEAN 15,000 14 10 30 1.5 Individual Working Hard 12 0 MEASUREMENT No. of Pieces No. of People Days Mins % -----Nos. Number of employees % POST LEAN 20,000 12 1.5 10 0.25 Team Working Smarter 6 6 IMPROVEMENT 33% 14% 85% 67% 83% Enjoying Work 50% 50%
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80
78%
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Case study Contd.. Summary of Improvements Qualitative Data

Some of the Major Improvements made are as follows: Visual Boards & Controls were Displayed Checking and Operating Instruction were displayed Raw Material Storage Racks was put in place Gangways were painted and marked ( To be painted quarterly ); Place for every thing was established One touch pick up of tools and gauges shadow board were established Suggestion Scheme and Kaizen was implemented effectively Process Measures were identified to Know status, establish targets and improve the parameter 29

Some of the Major Improvements made are as follows : - Contd.. Jigs and Fixtures were identified for reducing cycle time Files Retrieval easy Z marking Zones were established with accessibility to zone easy to reach /inspect/Entry/Exit/Direction in Zone marked Each Zones were numbered and listing of all zonal items with Photograph was made available Limit Sample Displayed Nothing on the Floor, Local red tag area marked, Nothing in the Gangway etc such system were established 30

Some of the Major Improvements made are as follows : - Contd.. Display Number of Kaizens suggested by the Zonal Members OPL ( One Point Lesson) were displayed Dos and Donts Mapping of Lights and Fans Cleaning Schedules were made Jigs, fixtures and tools identification for easy retrieval Cupboard were clean and items were arranged neatly
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Some of the Photos on Improvements made are as follows
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Some of the photos on Improvements made are as follows : - Contd..
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Some of the Photos on Improvements made are as follows : - Contd..
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Lean Manufacturing
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Value A capability provided to customer at right time at an appropriate price as defined in case by the customer . Features of the product or service, availability, cost or performance are dimensions of the value
Waste Any activity that consumes resources but creates no value (Waste)
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What is Lean Lean production focuses on eliminating waste in processes ( i.e the waste of work in progress and finished good inventories ) Lean production is not about eliminating people Lean production is about expanding capacity by reducing costs and shortening cycle times between order and ship date Lean is about understanding what is important to the customer
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What is Lean Thinking Specify Value : - Can only be defined by the ultimate customer Identify the Value Stream - Exposes the enormous waste Create Flow - Reduce Batch Size and WIP Let the customer pull product through the value Stream - Make only what the customer has ordered Seek Perfection - Continuously improve quality and eliminate waste
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Lean provides tangible benefits Reduces costs not just selling price - Reduces delivery time, cycle time, Setup time - Eliminate waste - Seeks continuous improvement Improves Quality Improves customer rating and perceptions Increases overall customer satisfaction Improves employee involvement, moral, and company culture Helps transform manufacturers
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New Paradigm Non Blaming Culture Management creates culture where : Problems are recognized as opportunities It is okay to make a legitimate mistakes Problems are exposed because of the increased trust People are not problems they are the problem solvers Emphasis is placed on finding solutions instead of Who did it
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Increase profit by price increase
Increase profit by cost reduction
Profit Price Cost Price
Profit Cost
The old way : Price = Cost +Profit
The New way: Price - Cost =Profit

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Lean is not just a shop floor improvement process Lean is not a point solution but a continuous improvement process Lean practices and principles are not a just shop floor improvements OEMs are recognizing the importance of deploying lean Beyond the shopfloor in marketing, Design, Engineering, Finance, Procurement, Contracts, Quality and other administrative areas. Best companies are migrating lean Beyond the Shop floor
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Lean Manufacturing Introduction
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Lean Manufacturing Definition: Definition: The process that provides the highest level of productivity, safety and quality through an effective deployment of human resources, equipment and materials while maintaining the least amount of waste. Three Objectives of Lean Manufacturing Customer Process Worker
Highest satisfaction of needs
Total elimination of waste
Respect for human dignity 44

Characteristics of a Lean Manufacturing Process Process is under control with predictable output Work place is well-organized Process for the elimination of waste in place Product flow at single piece or in effective set of batches to maximize equipment and resource utilization All operations and work stations synchronized with customer demand rate (TAKT TIME or TARGET TIME) Inventory well managed at the lowest level (JIT) Optimal balance of work at production stations Smooth production schedule and steady workload
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5 Interdependent Lean Principles

Know and understand what the customer values in functionality, quality, and delivery Map all steps in creating the product. Identify and eliminate wastes
Right Things
Right Way
Produce to demand: The right part, at the right time, in the right amount Make the value stream flow.. Support by stability and flexibility
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Wastes
The Tip of the Iceberg
Rework Need Special Scrap Eyes to Reinspection see waste Engineering Time Management Time
Waste is like Iceberg only 1/7th is visible
Repair
Supply Chain Disruption Decreased Readiness Levels Loss of life
We call Schedule Delays them Field Failures Kaizen eyes
Decreased Capacity Loss of mission Decrease in the number units procured
Possible Loss of program
ZERO DEFECT CONSULTANTS Lean Manufacturing 3M Muda - Waste Mura - Inconsistency / Imbalance/Unevenness Muri - Strain
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KAIZEN KAI + ZEN = Change + Good made through Process Observation Under Kaizen Paradigms Essence of Kaizen Activity = Work + Muda(Waste) Work = Value Added Activity ( VA) + Non Value Added Activity (NVA) Expenditure = Cost + Waste Work = Cost = VA + NVA Expenditure = VA + NVA + Waste 49 KAIZEN Process Improvement Observation Zero Investment Least Money Little time Human Development / Empowerment
ZERO DEFECT CONSULTANTS Lean Manufacturing Kaizen and Visual Management
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Suggested Lean Implementation Approach

Start Conduct Gap Analysis Identify the Present Status Establish Lean Goals ( Measurable) Identify the lean Techniques Develop Lean Road Map Lean Kickoff by Top Management Training of Lean Techniques Implementation of Lean Techniques
N
Monitoring of results
Reporting Sharing of results within Cluster Continuous Monitoring Closure of project 51
Improve
Review of results
Action Plan to Bridge the gap
Suggested Lean techniques & Deliverables

Some of the techniques & Deliverables that can be implemented are as follows : Lean Techniques Cellular Manufacturing Mistake proofing 7 Toyota Wastes 3M ( Muda, Mura, Muri) 5S Kaizen SMED TPM (OEE) Deliverables Improved Takt Time Improved Productivity Reduced Lost Time due to Accidents Reduced Rejection Reduced Rework Improved Delivery Improved Employee Participation Reduced Cost Improved Delivery
- Contd..
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Suggested Lean techniques & Deliverables

Some of the techniques & Deliverables that can be implemented are as follows : Lean Techniques Identified in the previous slide Deliverables Improved OEE Reduced Un Planned Down Time Reduced Inventory Reduced Set up Time Improved Cycle Time Reduced Customer Line Stoppage Reduced Customer Delivery Complaints Reduced Premium Freight Improved Inventory turnover ratio
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Thank you
Incase of any clarification or queries, please contact
Zero Defect Consultants

No.150, 12th cross, 16th Main , Sri Manjunatha Society, B T M layout I Stage, Bangalore 560029 Ph No. 080-26842672, 080-41200168 Email : zdconsultant@satyam.net.in Mobile: 080-9341262149 / 9741303741
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ZERO DEFECT CONSULTANTS Lean Manufacturing

Lean Manufacturing Implementation and its Roadmap

By. Dr. S M Jagadish

ZERO DEFECT CONSULTANTS Lean Manufacturing

ZERO DEFECT CONSULTANTS Lean Manufacturing

ZERO DEFECT CONSULTANTS Lean Manufacturing

Consultants Profile Contd..

ZERO DEFECT CONSULTANTS Lean Manufacturing

Consultants Profile Contd..

ZERO DEFECT CONSULTANTS Lean Manufacturing

Company Profile - Zero Defect Consultants

ZERO DEFECT CONSULTANTS Lean Manufacturing

Company Profile - Zero Defect Consultants Contd.

ZERO DEFECT CONSULTANTS Lean Manufacturing

Company Profile - Zero Defect Consultants Contd.

ZERO DEFECT CONSULTANTS Lean Manufacturing

Experience of Cluster Approach

ZERO DEFECT CONSULTANTS Lean Manufacturing

Experience of Cluster Approach

ZERO DEFECT CONSULTANTS Lean Manufacturing

Cluster and its Problem

ZERO DEFECT CONSULTANTS Lean Manufacturing

Cluster and its Problem Contd..

ZERO DEFECT CONSULTANTS Lean Manufacturing

Cluster and its Problem Contd..

ZERO DEFECT CONSULTANTS Lean Manufacturing

Cluster and its Problem Contd..

ZERO DEFECT CONSULTANTS Lean Manufacturing

General Approach for Lean Mfg Implementation

ZERO DEFECT CONSULTANTS Lean Manufacturing

General Road Map for Lean Mfg Implementation

ZERO DEFECT CONSULTANTS Lean Manufacturing

General Road Map for Lean Mfg Implementation

ZERO DEFECT CONSULTANTS Lean Manufacturing

General Road Map for Lean Mfg Implementation

ZERO DEFECT CONSULTANTS Lean Manufacturing

General Road Map for Lean Mfg Implementation

Review 9 10 Monitoring Management Review

Corrective Actions / Review Gaps and Pending Continual Improvements Actions

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

Phase 2 : Deployment of Value Stream Mapping

Improved Takt Time Improved Productivity

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

3rd week of 8th month to 2nd week of 9th month

Setup Reduction (SMED) -

Reduced Set up Time Improved Cycle Time Improved Productivity

Training Structured Deployment System Establishment

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

ZERO DEFECT CONSULTANTS Lean Manufacturing

Phase-wise Deliverables / Performance indicators

Phase 10 Corrective Action / Continual Improvements ----------------------------

ZERO DEFECT CONSULTANTS Lean Manufacturing

Experience in Lean Mfg Consultancy Projects Case study