Lean Manufacturing 2

1
Lean
Manufacturing
Visual Systems
2
Lean Building Blocks
Continuous Improvement
Pull/Kanban
Quick Changeover
Quality at Source
Cellular/Flow
Batch Reduction
Plant Layout
TPM
Standardized Work
5S System
Visual Systems
POUS
Value Stream Mapping
Teams/Employee Involvement
Source The MEP Lean Network
3
Visual Factory

• Ability to understand the status of a production
  area in 5 minutes or less by simple observation
  without use of computers or speaking to anyone.

4
5S
Method for creating and maintaining an
organized and clean workplace.
5
(No Transcript)
6
1S - Sort - Seri
Separate and Discard
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1S - Sort - Seri

• Identify all necessary and unnecessary items.
• Move unnecessary items from workplace to a
  designated area or throw it out.
• Remove all excess items from working areas work
  pieces, personal items etc.
• Organize all remaining necessary items.
• Designate a team to hunt down unnecessary
  items.

8
2S - Stabilize - Seiton
Set in Order Straighten Arrange and identify
for ease of use
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2S - Stabilize - Seiton

• Locate materials and tools at POINT- OF- USE
  (POUS).
• Store items needed by most people in a common
  storage area.
• Make items easily identifiable and easy to
  obtain.
• Label all containers, totes, supplies etc.
• Storage areas, work areas, containers should have
  floor marking and identifying labels.
• Place Maintenance/Operator instructions close to
  the point of use.
• Use special device (carts/shelves/racks) to
  organize tools and fixtures.
• Performance boards daily/weekly production,
  scrap/rework rate chart.

10
2S Visual Controls

• Label Containers, Cabinets, Supplies,
  Inventory, Machines, Tools, Scrap, Rework,..
• Color Parts container, floor markings,
  safety, work areas, trash cans,..
• Green Shipping, Yellow Work in process, Blue
  Storage/Trash.
• Checkered Aisles.
• Footprints Anything that is movable.
• Tool Boards Shadow board, Peg board.
• Performance Boards Hour by hour, 5S
  Measurement,
• Standard Work visible.
• Re-order points, Inventory levels.
• Material Flow indicators within, into, out of
  your cell.
• Equipment related information.
• Documents on safety, quality,

11
3S - Shine - Seiso
Clean up Scrub
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3S - Shine - Seiso

• Use dust collecting devices to prevent possible
  dirt.
• Ensure that electrical and other cords are not a
  hindrance to all personnel.
• Operators should clean their work area and
  equipment and perform preventive maintenance.
• Keep everything clean for constant state of
  readiness.

A Clean Workplace enhances QUALITY, SAFETY, and
PRIDE.
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4S - Standardize - Seiketsu
Keep Clean
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4S - Standardize - Seiketsu

• Implement a plan to keep the workplace clean all
  the time
• No unnecessary items, mess, dirt
• Who?
• When?
• How?

15
5S Schedule
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5S - Sustain - Shitsuke
Motivate
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5S - Sustain - Shitsuke

• Commitment
• Adherence
• Cell meets 5S principles at the end of each shift
• 5S Daily Checklist

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5 Minute 5S
Five Minute 5S Five Minute 5S Five Minute 5S
Area Area Contact
Sort Remove unwanted tooling (red tag to holding area) Remove unwanted tooling (red tag to holding area)
Set Mark out product variants (floor tape from Joe) Mark out product variants (floor tape from Joe)
Shine Degrease banjo press (gloves, solvent from Joe) Degrease banjo press (gloves, solvent from Joe)
Standardise Why is banjo press greasy, Why are variants mixed Why is banjo press greasy, Why are variants mixed
Sustain Who is/are responsible for press Who is/are responsible for press