2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,1,Introduction to Lean Manufacturing, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,2,One Page Overview,The purpose of lean is to remove all forms of waste from the value stream. Waste includes cycle time, labor, materials, and energy. The chief obstacle is the fact that waste often hides in plain sight, or is built into activities., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,3,Contents,Benefits of Lean Manufacturing The Origins of Lean Manufacturing What Is Lean Manufacturing? Waste, Friction, or Muda Lean Manufacturing and Green Manufacturing/ ISO 14001 Some Lean Manufacturing Techniques Conclusion, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,4,Benefits of Lean Manufacturing,Lean manufacturing delivers an insurmountable competitive advantage over competitors who dont use it effectively., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,5,Benefits of Lean Manufacturing,Lower production cost higher profits and wages Cost avoidance flows directly to the bottom line. Supports ISO 14001 and “green“ manufacturing Reduction of material waste and associated disposal costs higher profits Shorter cycle times: make-to-order vs. make-to-stock, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,6,Bottom Line and the Language of Money,The first comprehensive implementation of lean manufacturing yielded: Stock appreciation of 63 percent per year, for 16 years (not counting dividends) 7.2 percent annual wage growth The next section will discuss lean manufacturings origins., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,7,The Origin of Lean Manufacturing,Discussion question: Who created the Toyota Production System?, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,8,The Creator of the Toyota Production System, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,9,Origin of the Toyota Production System,Taiichi Ohno said openly that he got the idea from Henry Fords books and the American supermarket. Fords My Life and Work (1922) describes just-in-time (JIT) and other lean concepts explicitly. Depletion of supermarket shelf stock triggers replenishment; it is a “pull“ system like kanban or Drum-Buffer-Rope., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,10,Bottom Line Results of the TPS,The Ford Motor Companys original stock grew 63% per year (not counting dividends) and 7.2% annual wage growth. Toyota recently superseded General Motors as the worlds largest automobile company. The next section will show how the TPS delivers these results., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,11,What is Lean Manufacturing?,A systematic approach to the identification and elimination all forms of waste from the value stream., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,12,Concept of Friction, Waste, or Muda,Understanding of friction, waste, or muda is the foundation of the lean Manufacturing., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,13,The First Step is to Recognize the Waste,This principle has been stressed by: Henry Ford Taiichi Ohno (Toyota production system) Tom Peters (Thriving On Chaos) Shigeo Shingo J. F. Halpin (Zero Defects), 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,14,Waste Often Hides in Plain View,We cannot eliminate the waste of material, labor, or other resources until we recognize it as waste. A job can consist of 75 percent waste (or even more). Classic example: brick laying in the late 19th century, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,15,Waste is Often Built Into Jobs,Pre-Gilbreth Bricklaying, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,16,This is a Real Example,Top: “The usual method of providing the bricklayer with material“ (Gilbreth, Motion Study, 1911). Bottom: “Nonstooping scaffold designed so that uprights are out of the bricklayers way whenever reaching for brick and mortar at the same time.“, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,17,Post-Gilbreth Brick Laying,The solution is obvious (in retrospect), but first we have to know that we have a problem!, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,18,Another Example: Fabric Folding,Redesign of this job to eliminate the need to walk doubled its productivity. We will see that material waste also hides in plain sight., 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,19,Material Waste Hides in Plain Sight,Cleaning Tank 1,Cleaning Tank 2,Dirty parts,Clean parts,Clean Water,Discard water,Clean Water,The parts get clean, so no one questions this. What is wrong with this picture?, 2009, Levinson Productivity Systems, P.C. www.ct-yankee.com,20,Why Not Make the Water Work Twice?,Cleaning Tank 1,Cleaning Tank 2,Dirty parts,Clean parts,Discard water,Clean Water,The almost clean water from the second tank is good enough for use in the first tank. Water usage can be cut 50 percent.,