ABSLPowerSolutions2007 STMQualityLimited

STM Quality
Limited
Introductionto
LeanManufacturing
TOTAL QUALITY MANAGEMENT
Lean Manufacturing
STMQualityLimited
STM Quality
Limited DefinitionofLeanManufacturing

Theproductionofgoodsusinglessof
everythingbyreducingwasteandincreasing
valueaddedactivity

Ifitdoesntaddvalue,itaddscost!

STMQualityLimited
STM Quality
Limited PreparingforLeanManufacturing
FiveLeanPrinciples
Specify Value

Identifywhatthe
customeractuallywants
Wouldyoupayfor
somethingyoudidnt
want?
Ifitsnotaddingvalue,
itsaddingcost!
Identify the
Value Stream
Identifythewholeprocess
(mapping)
Whatarethefactsabout
ourprocesscapability?
Whatwasteistherein
theprocess?
Make product
flow
Eliminatebottlenecksor
managethembetter
Reduceoravoidbatch&
queue
Getthemaintenance
right
Let the
customer pull
Onlymakewhatthe
customerrequires,when
thecustomerwantsit.
Continuous
Improvement
Increasingpersonal&
companyknowledgeto
pursuethecomplete
eliminationofwaste.
STMQualityLimited
STM Quality
Limited
PreparingforLeanManufacturing

Reduction&eliminationofwasteelementsintheprocess

EquipmentreliabilityPlannedPreventativeMaintenance(P.P.M.)

AutonomousMaintenance&ConditionMonitoring

Continuousflow-onepartatatime(JIT)&pullKanbansystems

Inventory(WIP)reductionthroughouttheprocess

Defectreduction-rightfirsttime,errorproofing&training

Visualmanagementsimplemeasures(KPIs)&drumbeat

Quickmachinechangeovers(SMED)

Teamwork&communication

Pointofusestoragebutnotnests

Bottleneckmanagement

Sowhatdoesbestlooklike?
STMQualityLimited
STM Quality
Limited
PreparingforLeanManufacturing
Disorganised

Organised

STMQualityLimited
STM Quality
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ProcessMapping

Aprocessis

Asetofactivitieswhichconvertinputstooutputsto
meetagreedcustomerrequirements.

Drawaflowchartofwhatyoudo.Untilyoudo,youdo
notfullyunderstandwhatyouaredoing,youjusthave
ajob

DrW.E.Deming
STMQualityLimited
STM Quality
Limited
ProcessMapping

Characteristicsofanidealprocess

Eachstepaddsvalue

Eachstepiscarriedoutonlyonce

Stepsarecarriedoutinthebestsequence

Usestheoptimumlevelofresource

Meetscustomerneedsconsistently

Minimumspacerequirements
STMQualityLimited
STM Quality
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WhyProcessMap?

Biggesttoolinleanallothersaredeployedfrommapping
output

Bigpicturedetailcomeslater

Establishesrealprioritiesbythosewhodotheworkaction
planswithnames&dates

Dramaticshort&medium-termresults

Ideageneration&teaminvolvementindecisionmaking

STMQualityLimited
STM Quality
Limited
ProcessAtlas
Customerneeds
CORE PROCESSES
SatisfiedCustomer
KPIs
MANAGEMENT PROCESSES
STRATEGY
DATA
SUPPORT PROCESSES
RESOURCES
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STM Quality
Limited
BoundariesandScope

Starttofinishorderenquirytoreceiptofpaymentortighter
definitionwecaninfluence?

Allpossibleproductsorrunnersonly?Thinkflow&volume

Whatfunctionsdoweneedinvolvedbeyondthisroomboth
internal&external?

Isthereanobviousneedformoreinformationatthisstage?
STMQualityLimited
STM Quality
Limited
LeanWastes

The8LeanWastes(7+1)

IntroductiontoTIMWOODS

STMQualityLimited
STM Quality
Limited
TIMWOODS
T Transport
I Inventory
M Movement
W Waiting
O Over-processing
O Over-production
D - Defects
S - Skill