Ten Steps to Lean Production

CIMT 100 Fall 2003

Adapted from: Black, J T. and S. L. Hunter (2003). Lean Manufacturing Systems and Cell Design. Dearborn, MI, Society of Manufacturing Engineers.

Working up to CIM and Lean Production

Steps to CIM
1. Re-engineer the manufacturing system
Form U-cells to produce families of parts Integrate production, inventory, QC and machine tools Pace cell by takt time Poka-yoke

Steps to CIM
2. Setup reduction or elimination
Identify elements that are internal and those that are external Improve methods (pit crew) Reengineer to eliminate adjustments, mechanize, automate

Steps to CIM
3. Integrate quality control into the system
Develop a systems approach Incorporate visual signals Work toward a 1 piece flow
Make 1, check 1, move 1 on

Steps to CIM
4. Integrate preventative maintenance into the system
Reduce pressure on workers and the process (back off from 100%) Housekeeping place for everything and everything in place Decrease system variability

Steps to CIM
5. Level, balance, sequence and synchronize
Smooth manufacturing Keep production level Make production predictable Incorporate kanban signals

Steps to CIM
6. Production Control
Integrate the scheduling and control functions into the system MRP/ERP software (with a twist!) Use the PC system to link cells together

Steps to CIM
7. Reduce work-in-process
Excess inventory hides problems Lower the inventory to expose problems Take immediate action to eliminate the problems

Steps to CIM
8. Integrate suppliers
Work to reduce suppliers to a single source Develop trust and open communications Implement flexible procurement contracts Develop long-range forecasts

Steps to CIM
9. Autonomation
Allow workers to control the process (no fear) Provide clear directions
TOYOTA calls it True North

In-process controls and inspections Decouplers as needed Feedback loops

Steps to CIM
10.Computer-Integrated Manufacturing
Enterprise-wide systems Remove functionality of Departments Focused teams on product lines and customers

The REAL Goal is to become LEAN

Waste eliminated Employees involved Customers satisfied Profits increased Company survival assured

Not really a staircase !

The steps are really NOT the stairs that are a path to lean. Toyota has been on a journey toward a waste free and coordinated operation for 45 years and they know they are not there yet. The steps and tools help people understand the process of change, but there is much more that is required You are in the right major! CIMTs will help companies get CIM and become LEAN