Académique Documents
Professionnel Documents
Culture Documents
K.B.Gopalam
Aura Leadership Foundation
Hyderabad
Lean Production
• assembly-line manufacturing methodology.
• as "to get the right things to the right place at
the right time, the first time, while minimizing
waste and being open to change".
• eliminating waste,
• improved product flow and better quality.
• deliver on demand, minimize inventory,
maximize the use of multi-skilled employees,
flatten the management structure, and focus
resources where they were needed.
The Ten Rules of Lean
Production
1. Eliminate waste
2. Minimize inventory
3. Maximize flow
4. Pull production from customer demand
5. Meet customer requirements
6. Do it right the first time
7. Empower workers
8. Design for rapid changeover
9. Partner with suppliers
10. Create a culture of continuous improvement
Gemba Kaizen
• Gemba means `real place' meaning the area
where value is actually added,
• Kaizen means continuous improvement.
• to reduce costs, cut out waste, improve
quality and productivity.
• without using expensive technologies.
The Impediments
• the misconceptions regarding the theory
• that it needs to be done by workers, not
managers
• management of shop floors left to middle
managers and supervisors
• visit the shop floor ?
1. Seiri (Clearing Up)
wastebasket is our friend.
– plenty of waste receptacles.
– a waste container was within six steps.
• of any position.
• E-bay also is your friend.
– Serviceable but unwanted equipment
– can be auctioned off.
• Three-tier classification.
– Frequently-used items at workstation.
– Regular use: near workstation.
– Rare use: keep outside the work area.
2. Seitori (arranging)
1. What is to be shined?
2. Who is responsible?
3. How will it be shined?
4. What is needed to shine?
5. Implement Shine (everyone’s responsibility in a
work area)
6. 5S Schedules – Have a plan…
7. 5 Minute Shine – Quick & easy!
Standardize
• Making It A Habit
Assigning three discipline job
responsibilities
Integrating three pillar duties into
regular work duties
Checking maintenance of the three
pillars
• Prevention
what they are responsible for doing and
exactly when, where, and how to do it.
Sustain
o 5S Slogans
o 5S Posters
o 5S Photo Exhibits
o Story boards
o 5S Newsletters
o 5S Pocket Manuals
o 5S Department Tours
o 5S Months
o Success Stories
Another Version
1. Sort:
Decide which things you need to accomplish your
work.
2. Straighten:
Decide what are the things you do not need. You
should get what you need in 30 seconds.
3. Sweep:
perform maintenance regularly.
4. Standardise:
Standardise the procedures.
5. Self Discipline:
Make the employees a party to the plan.