developed in manufacturing
benefits
- reduced cost
- reduced lead and cycle times
- improved communication between customer and organization
- reduced work space needs
- process flexibility facilitated
five laws of lean
- law of the market
* customer is highest priority * focus every process toward customer satisfaction 2. law of flexibility * speed at which process can run related to adaptability of process 3. law of focus * Pareto principle 4. law of velocity * velocity of process inversely proportional to work in progress (WIP) * greater WIP means greater lead time 5. law of complexity * complexity creates more waste than slow processes or poor quality
created by Toyota based on production concepts of Henry Ford
key concepts of lean
- value : rating of how well product meets customer needs
- value stream : processes that produce valueable products
- pull : demand production rather than production based on forecasts
- perfection : aim for constant improvement
- waste steps
- activities that don't add value
steps to applying lean
- identify what creates value, according to customer
- identify value stream
- shift to pull production
- review and optimize processes
lean tools
five S's
- sort : remove unneeded items
- straighten : arrange and organize necessary items
- shine : cleanliness and repair
- standardize : maintaining environment by regular maintenance
- sustain : making steps standard process
benefits
- greater efficiency
- reduced defects
- greater safety
JIT ( Just in Time)
- materials should be devlired just when needed
- reduced inventory
Kanban (signal)
- inventory control system that indicates when material is needed
- advantages -- reduced setup and manufacturing time -- improved quality and inventory control
- disadvantages -- no inventory buffer
value stream mapping
- charting steps in the value stream
Kaizen(continual improvement)
- process improvement through incremental steps
- "Kaizen blitz/event" - intense focused improvement process, lasts about a week
mistake proofing(poka yoka)
- created by Shigeo Shinjo as part of Zero Quality Control (ZQC)
- devices which prevent errors like the french fry packers at McDonald's