Eliminating Waste

in Manufacturing
Lean Manufacturing
4 Components to Lean Implementation
Lean
Manufacturing
is a collection
of tips, tools
and
philosophies
that eliminate
waste,
improving the
overall quality.
Lean
Culture
Lean
Concepts
Lean
Planning
Lean
Tools
A set of guidelines
or standards that
one should live &
work by
Constantly
changes as the
environment
changes
Mindset & attitude
about how things
are carried out
Brings leadership,
communication,
teamwork &
empowerment
together
The path to
develop your
leaders, employees
and problem-
solving skills
Lean Culture
Lean Concepts:
8 Deadly Wastes
1. Overproduction 5. Motion
2. Waiting 6. Over Processing
3. Transportation 7. Inventory
4. Defects 8. Under Utilizing People

Recognize
waste
Identify
the
causes
Process
to
eliminate
waste
Do You Do The 8 Deadly Wastes?

1. Overproduction- produce more than consumers demand
2. Waiting- lag time between production steps
3. Transportation- move materials carelessly
4. Defects- time spent finding & fixing production mistakes
5. Motion- people & equipment move ineffectively between
tasks
6. Over Processing- work on product more than once
7. Inventory- supply levels too high
8. Under Utilizing People- use workers inadequately




Shown in
the pictures
are ways to
use
employees
efficiently,
as well as
how to
transport
products
properly.
Sense of
Urgency
Guiding
Coalition
Vision and
Strategy
Communication Affirmation
Lean Planning
The
organizations
goal to create
value by
improving
efficiency.
Leading Charge is being the head of a new idea, direction or project.
5 Leading Charges
Value Stream Map
Value Stream Mapping uses diagrams and charts to
visually analyze and design the flow of materials
to spot any bottleneck areas or inefficiencies to
rid your overall process of any wastes.






Identify product
Draw current
map showing
steps, delays
and info
Assess map in
terms of
creating flow to
eliminate waste
Draw a future
value stream
map
Work towards
the future goals
Lean Tools
1. 5S- organize the work area by sorting, setting in
order, shining, standardizing and sustaining.
2. Andon- visual feedback that acts as a real-time
communication tool for the plant floor, bringing
immediate attention.
3. Bottleneck Analysis- identify parts that slow down
the process to improve productivity.
4. Kaizen- continuous improvements that are
accomplished by placing strategies for employees to
work together.
5. SMART Goals- Specific, Measurable, Attainable,
Relevant and Time-specific.
6. Total Productive Maintenance (TPM)- empowers
operators so that they maintain their equipment and
encourages more involvement and pride.



Although
there are
numerous
lean tools,
these are
just a few
Lean Tools
7. Continuous Flow- smoothly flows to eliminate
wastes
8. Gemba (The Real Place)- get out from desk & spend
time on the plant floor
9. Heijunka (Level Scheduling)- production scheduling
that reduces lead times & inventory
10. Jidoka (Autonomation)- equipment partially
automated so workers can monitor several
stations at once
11. Just-In-Time (JIT)- parts are pulled based on
customer demand, not projected demand.
12. Muda (Waste)- eliminate everything in process
that does not add value to customer.
Profit
People Process
Lean
Corporate strategies
Product/Service Lines
Sales strategy
Marketing strategy
Engagement
Development
Morale
Respect

Business Processes
Stability/Capability
Technology
Quality outcomes

Lean Cycle
For more information visit www.distran.com
or email us at info@distran.com or call at
(318) 448-0274.

DIS-TRAN Steel, LLC
4725 Hwy 28 E
Pineville, LA 71360
Contact Us For Any
Questions