Lean Manufacturing

Unit 1 - Lean Concepts

Lesson 1: Why Lean? Be customer focused:

• Be on-time, responsive, flexible, and fast. Simplify and standardize workflows: Mimic continuous flow, minimize WIP, use visible measures. Manage capacity: Increase process uptime, reduce set-up times, find “lost” capacity. Eliminate waste: Identify non-value adding activities, then modify, combine, or eliminate those tasks. JIT: Not too early and never late; not just-in-case inventory but
• Be customer focused: Be on-time, responsive, flexible, and fast. Simplify and standardize workflows: Mimic continuous flow, minimize WIP, use visible measures. Manage capacity: Increase process uptime, reduce set-up times, find “lost” capacity.
• Eliminate waste: Identify non-value adding activities, then modify, combine, or eliminate those tasks. JIT: Not too early and never late; not just-in-case inventory but just-in time production and delivery; products must always be made right the first time; equipment must always work when needed.

Lesson 2: Lean Terminology Terms Tools Techniques

Lesson 3: Eliminate Waste with Lean Match lot sizes to customer demands:

• Use kanbans; end WIP. Use pull scheduling instead of push
• Use kanbans; end WIP. Use pull scheduling instead of push scheduling. Schedule to the rate-determining step (the bottleneck., then debottleneck process lines. Facilitate fast feedback: Arrange sequential operations next to each other ensures fast feedback from internal customer operation to internal supper operation if something in-process is not right.

Lesson 4: Components of Lean Overview of the 8 Components of Lean:

• Value Stream Mapping, Workplace Organization, Predictability & Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, & Continuous Improvement.
• Value Stream Mapping, Workplace Organization, Predictability & Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, & Continuous Improvement.
• Lesson 5: Value Stream Analysis Mapping the process from incoming order to outgoing product:
• Define process goals, create the current state map, & establish process metrics. Using the current state map to identify potential improvements, conceive the future state.
• Define process goals, create the current state map, & establish process metrics. Using the current state map to identify potential improvements, conceive the future state.

Lesson 6: Lean Thinking Eliminating waste is not limited to manufacturing; 

• The same techniques apply to the office, sales, finance, maintenance, and even R&D processes and procedures. Lean & Six Sigma are complementary
• And much more