LEAN

MANUFACTURING
Jason Prior
Introduction to Lean
Overview of Lean in Toyota video.
Main Concept: ELIMINATING WASTE
Not an acronym
Not a new concept has been in development
for over 200 years.
Example: A Lean person is someone who is
quick, has little fat, flexible and effective. The
same can be said for a Lean organization.
Value Stream
Value Stream video
Approximately 95% of a value stream is waste
or non-value added time
Value stream mapping visually maps the flow
of materials and information through all
processes until the product reaches the
customer.
Purpose of value stream mapping is to identify
non-value added actions so they can later be
improved/eliminated.

Value Stream Map- John Deere

Types of Waste or Muda
1. Transportation
2. Inventory
3. Unused Creativity
4. Waiting
5. Overproduction
6. Complexity
7. Defects
Customer Pull and Kanban Systems
A method of controlling the flow of production
through the factory based on a customers
demand
Alternative to producing according to a forecast
If you read this say I watch barney out loud now
Implementation will reduce lead times, minimize
work in process, optimize floor space usage,
simplify production signals and improve on-time
delivery to your customers.
Kanban Example
Kanban mean visual record in Japanese
An example
Just in Time
Parts arrive through the supply chain shortly
before they are needed for production
Inventory Strategy that a business implements
to reduce work in process (WIP).
Must be coordinated with suppliers
Saves Space
5S Organizing a Workplace
Sort- red tagging; anti-just in case attitude
Set in Order- "A place for everything and
everything in its place."
Shine- Clean so malfunctions easier to spot
Standardize- simplify the process so easy to
repeat and sustain
Sustain- never finished
5S
Sort Set in Order
5S Shoe Factory Indonesia
Before After
Continuous Improvement (Kaizen)
Improvements should be made both radically and
incrementally
Radical improvements include overhauling a batch
system into a flow system
Incremental improvements focus on attacking waste
in the value stream
Vital to create a vision of the process and eliminate
waste one step at a time to achieve the goal
Compete against perfection as well as competitors.
Homework
It is obvious that 5S is successful in manufacturing environments.
However, watch this video and write two thorough responses on
your opinion of 5S in an office environment. Choose two of the
following topics:
Would you mind 5S-ing your desk space? Why or Why not?
Do you think a 5S office space would make an employee
more efficient/productive?
Many people have their own organization methods. Would it
be more effective to adopt 5S or allow employees free reign?

http://online.wsj.com/article/SB122505999892670159.html#video=
08C6384E-D821-4E06-8D3C-
7127672621CF&articleTabs=video
The Lean Manufacturing
Game
The Rules
Rules
1. Divide into 2 equal teams
2. There will be 8 available questions to choose
from. The two teams will alternate choosing
and answering questions.
3. 1
st
question =100 ; 2
nd
question=200;
3
rd
question =300 ; 4
th
question =400
4. If a team answers incorrectly the other team
has the chance to steal the points
5. Each team gets one Super Question which
adds 200 points to the questions value.

Put Away All Materials Now
The Questions
Question 1
Question 2
Question 3
Question 4



Question 5
Question 6
Question 7
Question 8

Question 1
Name four types of waste in a Lean
environment.

Answer
Question 2
The Toyota Production System was largely
influenced by the Ford model. However, name
an improvement made by Taiichi Ohno and the
Japaneses that made the TPS much more
effective.
Answer

Question 3
Briefly explain the concept of a pull system
Answer

Question 4
What is the overall concept of Lean in two
words?
Answer

Question 5
Name the person accredited for perfecting
interchangeable parts.
Answer
Question 6
What is the purpose of mapping a value stream?
Answer

Question 7
What is the definition of value added?
Answer

Question 8
Name all 5 Ss in order
Answer

Answer Question 1
1. Transportation
2. Inventory
3. Unused Creativity
4. Waiting
5. Overproduction
6. Complexity
7. Defects
Main Questions
Answer Question 2
JIT
Working conditions
Team development
Cellular manufacturing
Flexibility
Kanban systems
Quality circles
Main Questions
Answer Question 3
A method of controlling the flow of
production through the factory based on a
customers demand

Main Questions
Answer Question 4
Eliminate Waste
Main Questions
Answer Question 5
Eli Whitney
Main Questions
Answer Question 6
To identify non-value added actions so they
can later be improved/eliminated.
Main Questions
Answer Question 7
Something the customer is willing to pay for.
Main Questions
Answer Question 8
Sort
Set in Order
Shine
Standardize
Sustain
Main Questions