Lean_Manufacturing_Principles_Made_Easy.pdf

1、Lean Manufacturing Principles Made Easy Wings Of SuccessPage 1 of 1Lean Manufacturing Principles Made Easy Wings Of SuccessPage 2 of 2DISCLAIMER AND TERMS OF USE AGREEMENT:(Please Read This Before Using This Report)This information in this course is for educational and informational purposes only. T

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8、 SuccessPage 3 of 3Lean Manufacturing Principles Made Easy Wings Of SuccessPage 4 of 4Lean Manufacturing Principles Made Easy Wings Of SuccessPage 5 of 5Lean Manufacturing Principles Made Easy Wings Of SuccessPage 6 of 6Lean Manufacturing Principles Made Easy Wings Of SuccessPage 7 of 7ContentsWhat

9、Is Lean Manufacturing?.8Lean Manufacturing Tools .10Questions, Diagnostics And Assesments.12Areas In Business Where Lean Can Help.145 Steps To Enable Lean Manufacturing Into Your Business.16Lean Manufacturing And Consulting Firms In The UK .18Definition Of Lean Manufacturing .21Important Lean Manufa

10、cturing Terms : Definition .22Lean Manufacturing Led Signs.23Lean Manufacturing Consulting Ontario Canada.26Lean Manufacturing Principles.29Lean Manufacturing Processes.32Lean Manufacturing Towards Success .35Free Training On Lean Manufacturing.37Lean Manufacturing In The UK.40What Is Lean Manufactu

11、ring?.43Companies That Use Lean Manufacturing With Success.46Implementing Lean Manufacturing Systems.49Lean Manufacturing Books.52Lean Manufacturing Consultants.55Implementing The Lean Manufacturing Strategy.58Lean Manufacturing Printing Industry.60Lean Manufacturing Six Sigma.63The Benefits Of A Le

12、an Manufacturing System.65Move Ahead The Corporate Ladder With Lean Manufacturing Training.68The Philosophy Of Lean Manufacturing.71What Is Lean Manufacturing?.74The Lean Manufacturing Process .77Learning The Basics Of Lean Manufacturing And Processing.80When Is A Change In Management Required In Le

13、an Manufacturing?.83The Five Principles Of Lean Manufacturing.86Lean Manufacturing Principles Made Easy Wings Of SuccessPage 8 of 8What Is Lean Manufacturing?Why is Lean Manufacturing or thinking so prevalent in the modern current economies of scale?To remain competitive, agile and the lowest cost p

14、roducers, providers and streamlinedbusiness, getting rid of waste and being highly, consistently and sustainable is key for survivaland thriving in this new economy.Lean manufacturing or thinking is exactly what the name sounds like - it is about cut to thebone, fat-trimmed, streamlining operation a

15、nd organizations.Authors Womack and Jones define lean thinking as a set or collection of efficiency tools thatyou can unleash in your business to save money, reduce cost and waste and deliver consistentand effective service that is affordable and pleasing to your customers. It is about vision andtoo

16、ls for reducing variability and cutting down on waste, being efficient and running a smoothand competitive, even profitable operation, well.The thinking was initially championed by pioneers like Toyota and it was eventually adopted bythe Japanese automakers as the principle upon which they wanted to

17、 build, run and grow theirbusinesses. Only a little later, will the Western world catch onto the value and potential of thisapproach to their respective organizations and operations.Some have referred to lean manufacturing as the TOYOTA PRODUCTION SYSTEM, or JIT(just-in-time) manufacturing, paying a

18、ttention to things like flow productions, line operations,value streams, Kaizen (which we will get to later). In any lean manufacturing process andapproach there are a couple of things to pay attention to. There is discipline, planning, rigor,scientific approach and statistically-based tools require

19、d and applied to make this businessparadigm fit, work and last.Lean manufacturing will help you in your business take a serious look at visible causes andeffects in your business. Aspects that could get some attention could include things like:inventorymovement/motionLean Manufacturing Principles Ma

20、de Easy Wings Of SuccessPage 9 of 9waiting or queuesbroken machines or tools (missing)dirt and clutternoise and many others.Things that we can see that is obvious waste or inefficiencies attract attention and demandaction. This is where lean manufacturing steps in and makes the difference. It deals

21、with theproblems that we can actually SEE and do something about.Lean Manufacturing Principles Made Easy Wings Of SuccessPage 10 of 10Lean Manufacturing ToolsSome of the lean manufacturing tools that might be able to help you in your processes are:5SCellular ManufacturingMistake ProofingSet-Up Reduc

22、tionA basic fundamental tool in Lean manufacturing that can help any business the 5S approach isan organizing, structuring technique to get rid of clutter and waste. Cleanliness and having a setplace for everything is key.The name stems from the Japanese meanings and equivalent words forSorting thin

23、gs (seiri)Setting things in a particular order (Seiton)Shining, daily maintenance (Seiso)Standardization (Seiketsu)Sustainability (shitsuke)Cut costs and reduce waste by applying these simple techniques to your business today.Cellular manufacturing has to do with organizing not the workplace only bu

24、t the work as well.Work-cells and designated work- areas, certain spaces for certain activities, minimizesmovement of people and things, therefore costing less. In an operational sense this means nobatching, no waiting, no delays, no queuing, just smooth operation and easy flow.Mistake-proofing (Pok

25、a-Yoke)Built-in safeguards, reducing defects to zero is at the center of this approach. Highlightingproblems as they occur, not letting mistakes, oversights and errors slip through is key.Lean Manufacturing Principles Made Easy Wings Of SuccessPage 11 of 11Processes are designed around this principl

26、e to be more efficient and will help you business cutdown on cost, scrap and waste.(SMED or single minute exchange of dies ) Quick and speedy change-over in businessprocesses, manufacturing and operations are essential. Remember time and quality matters,means money! Process thinking is the key here.

27、 Getting rid of unnecessary steps, actions ormovement are key. Reducing time on any line, saves money.There is more to lean manufacturing that just these couple of tools. They just serve as anintroduction to some of the major business enablers that LM can bring to your business andorganization.Lean

28、Manufacturing Principles Made Easy Wings Of SuccessPage 12 of 12Questions, Diagnostics And AssesmentsYou can not change what you do not acknowledge or know about. Lean Manufacturing bringswith the appeal and awareness to take note and notice things around you (cost, waste,movement, clutter, scrap et

29、c.) and then DO something real, meaningful and constructive aboutit!What improvements should and could be made are both important questions to ask, prioritizeand act upon. Customer priorities, things that affect your incoming revenue should get attentionquickly and first. Things like quality, lead a

30、nd waiting, cycle time, cost, inventory and otherinternal processes that affect the customer and are internal and controllable, should be dealtwith expediently.In order to get you started asking the right type of questions could provide you with hints as to astrategy and starting point/priority:Whic

31、h process or step should get the bulk of our immediate attention where is the biggestWIN-WIN for both the customer and the company? What are all the priorities that we need topay attention to in this organization/business and operation, map the processes and make thelist. Then ask in what order you

32、should tackle the priorities? How do we get the BESTimprovements the quickest way? How do/can we tap into the benefits of LM right away?If reducing overhead, quality costs and inventory to save money, reduce weight and be asmooth operating, streamlined and cost-efficient provider are keys to your bu

33、siness success,LM can help your business in all aspects and areas.Taking the theory of LM to the practical implementation will take planning, patience andpersistence. Determination, detail orientation and discipline. We often refer to these as theTHREE ps and the THREE ds to make them easy to rememb

34、er. Gradual, planned, focusedeffort is what it is all about. Step-by-step instructions and actions to get to improvements overtime, that can be sustained, stable and predictable are essential. If any of the followingscenarios are important to your business, LM can help you reach targets and goals in

35、 this areathat you set for you, your team and your business:Lean Manufacturing Principles Made Easy Wings Of SuccessPage 13 of 13Increasing operating margin and revenueReduce manufacturing lead, wait and cycle timesLessen WIP or work-in-progress inventory (half-completed product), time and space cos

36、tsmoney! Reduce costsReducing manufacturing overhead and quality costsIncrease gross profit marginGet customers what they want, when they want it, anytime, every time and all the time, quicklyand correctly, affordably and on-demand.Achieve consistent quality and low defect rate (scrap/waste)Make the

37、 most of your shareholder value and you can not go wrong. Achieve high levels ofimprovement rates and customer satisfaction, quality products, low costs and do so quickly andyou remain competitive and profitable.Get and keep your processes under control and improve getting better all the time, setti

38、ng andpositioning yourself head-and-shoulders above the masses and mediocrity. Help define andexecute your competitive edge with a well-thought out, supported, gradual deployment,throughout or LM in your business and you are set for desired outcomes, success and results!Having a very real measurable

39、 impact and resulting dramatic improvements in your businesslistening to your customer complaints can give you great hints as to where some of theproblems might lie. DO NOT hesitate to ASK them! They will tell you. It is a wonderfulopportunity and channel to let your customers know that what they wa

40、nt, say and need,REALLY MATTERS. If you provide this levelLean Manufacturing Principles Made Easy Wings Of SuccessPage 14 of 14Areas In Business Where Lean Can HelpOther aspects of lean to consider for LM deployment in your business are as follows:LeadershipInitiative and leading by example from the

41、 top is key. The main flag-bearer and champion of thisLM process and initiative starts with the business leader (CEO/President) and the seniormanagement team. Buy-in and support can make or break the efforts of LM.Personal, hands-on, practical engagement, commitment, practice and even reward for ful

42、lparticipation in these initiatives, being the drivers of performance per se is critical to and for LMsuccess. Inspire and mobilize others.Corporate, business culture and infrastructure, support and championing of the LM effortscontribute to the momentum and success of it throughout the organization

43、.Include and engage EVERYONE! LM provides you the opportunity to harness and leverage thetalents of the entire workforce and collective, not merely a hand-full of individuals or someemployees. MAKE EVERYONE COUNT AND CONTRIBUTE!If lasting results and sustained top performance matters to you and your

44、 business here are themeans to that end in the LM toolkit!Metrics and goals make things easier to achieve and practically act upon, effect, change,impact, reshape etc. MAKE EVERY ASPECT OF YOUR BUSINESS COUNT!Infrastructure, support and deploymentShare the commitment, discipline and persistent toil

45、to get to where you need to be. It starts witheveryone, not just some! Have you customers front-of-mind at every step, process and corner ofwhat you are doing, planning, improving, know what they value, why and how to get it to themquickly, effectively, consistently and affordably, anytime, every ti

46、me! SHIFT YOUR FOCUS.Lean Manufacturing Principles Made Easy Wings Of SuccessPage 15 of 15Shareholder value and $ impact is a good guidelines for priorities and activity within LM.IMPROVEMENTS CAN/SHOULD BE MEASURABLE AND ACTAULLY TRACKED!Engage everyone in the process, assign roles and responsibili

47、ties and tap into the full potentialeveryone has to bring to the table. Committed resources, time and training (initial investment)will pay off quickly. Mobilize your workforce and enable, empower and energize them.Lean Manufacturing Principles Made Easy Wings Of SuccessPage 16 of 165 Steps To Enabl

48、e Lean Manufacturing Into Your BusinessHere are 5 easy tips of how to enable LM in your organization:1. Keep The Channels Of Communication OpenTalk and inform oftenEducate and empower, knowledge, skill, practice and competence, on-going mastery andteaching othersTrust, honesty and information = tran

49、sparencyGive everyone a head start, a common language, goal and purpose and unleash the power oflean on your organization.2. Give Opportunity For Everyone For Input And FeedbackGet everyone engaged, excited and hands-on, involved and aboard with your LM initiative andplansIntroduce feedback and coac

50、hing, establishing communication channels where before theymight have been none3. Create And Cultivate The Right Working Context And Environement Where Honesty IsAlways The Best Policy!Set communication and information sharing, learning and openness (transparency) as anorganizational priorityLess pe