Lean principles

Value, Value Stream, Flow, Pull, Perfection, Waste Types in Services, Waste Types in Manufacturing, Value Add, Non Value Add, 3 MU's, Gemba, Cycle Time, Lead Time, Takt, ECRS, Eliminate, Combine, Rearrange, Simplify, Sources of Waste, Excellence, Sustained,

1. Lean Principles
Anand Subramaniam

2. Lean Principles
2

3. Lean Principles
3
Deliver only what is needed,
when it’s needed
Complete elimination of non
value added activities
Avoid defects and bottlenecks (Rework, Errors, Waiting)
Eliminate steps that don’t
create value and cause waste
Most customers just want a
solution to their problem

4. Value
4

5. Deliver Value
5

6. What is Value?
6

7. Value (Non) Add
7

8. Where to focus?
8
NVA Time
99%
VA
1%
Order
Delivery
Focusing on non value added (NVA) has the largest
opportunity for improvement

9. Increase Value & Eliminate Waste
9

10. @ Gemba
10

11. Ohno Circle
11
Grasp
the
situation

12. 3 Mu’s
12

13. Review Current Process
13

14. @ Gemba –Observation Sheet
14

15. Waste Types
15

16. Sources of Waste
16
Sources
of Waste
No standards, non-
compliance with
standards
Equipment / system failures
Lack of integrated
systems & poor system
functionality
No method to
prevent and / or
catch errors
Poor communication
Disorganized
workspace
No visibility to
performance
Ineffective design /
layout of facilities
Fragmented, poorly
designed processes
Inadequate or no training
Unbalanced
workloads
Overburden or
unreasonable demand
Lack of information
Regulatory constraints

17. Waste in Manufacturing
17

18. Waste in Services
18

19. Time
19

20. Lead Time Reduction
20

21. Idle Time & Process Time
21

22. Takt, Cycle & Lead Time
22

23. Takt Time Calculator
23
Target
Actual
Notes
Rounded
Up

24. Value Stream
24

25. Why create a Value Stream?
25

26. How many Value Stream Participants?
26
7 +2
1/3 –SME / PO
1/3 –Cus/ Sup
1/3 -Outsider

27. Challenge the Status Quo
27

28. Current VSM & Waste Identified
28

29. Waste Removed & Future VSM
29

30. ECRS Work Analysis Sheet
30

31. ECRS -Questions
31

32. Lead Time Calculation
32
18,400/20
= 920/day
4,140/920
= 4.5/day

33. Some Errors !!
33
No Information
flows to process

34. Flow
34

35. Flow
35

36. Improved Flows
36

37. Pull
37

38. Push vs. Pull
38

39. Perfection
39

40. Lean Pillars –Strive for Perfection
40

41. Strive for Excellence
41

42. Sustain the Improvement
42

43. 43
Good Luck
http://www.linkedin.com/in/anandsubramaniam