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Effective Lean Implementation Techniques to Achieve Bottom Line Results

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How long does it take for value stream mapping? 6 weeks? 4 weeks? 1 week? ... Audit lean results for sustainability integrated with ISO auditing techniques ... – PowerPoint PPT presentation

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Title: Effective Lean Implementation Techniques to Achieve Bottom Line Results


1
Effective Lean Implementation Techniques to
Achieve Bottom Line Results
  • Presented By Baskar Kotte
  • Quality Systems Enhancement, Inc.
  • 1790 Woodstock Road
  • Roswell, Georgia 30075
  • Toll Free 1-866-577-4476
  • baskar_at_enhancequality.com
  • www.enhancequality.com

2
Lean The QSE Focus
3
Lean
  • Not just lean manufacturing
  • Lean is an enterprise
  • Lean enterprise covers all areas of business

4
Lean Enterprise Focus
  • Achieve more with less
  • Minimize inventory at all stages of production
  • Improve machine efficiency and delivery
    performance
  • Eliminate waste of all kinds (time-material)
  • Error-proof process with problem solving
    techniques
  • Reduce purchasing cost and customer credits
  • Improve information system
  • Improve quality and customer satisfaction

5
Definition of Lean Enterprise
  • Lean enterprise is a balanced organization

Discipline
Problem solving
Empowered Employees
ISO
6
Definition of Lean Enterprise
  • Causes of failure

Not my job I am the Boss
No discipline
No problem solving
No commitment
7
Lean Tool Mumbo Jumbo
  • Value stream mapping
  • Quality at the source
  • Workplace organization 6S
  • Total Productive Maintenance (TPM) and Overall
    Equipment Effectiveness (OEE)
  • Visual management
  • Batch size reduction
  • Cellular manufacturing
  • Work balancing (TAKT-time)
  • Production leveling / smoothing
  • Point-of-use systems
  • Kanban
  • Kaizen
  • Single Minute Exchange of Dies (SMED)
  • Standardized work
  • Statistical Problem Solving (SPS)
  • Balanced Scorecard

8
Lean Tools for the Box Industry
  • Value stream mapping
  • 6S
  • Visual management
  • Statistical Problem Solving (SPS) techniques
  • Total Productive Maintenance (TPM) and Overall
    Equipment Effectiveness (OEE)
  • Work balancing (TAKT-time)
  • Kanban
  • Kaizen
  • Single Minute Exchange of Dies (SMED)

9
Understanding Selected Tools and Techniques
Value Stream Mapping
  • How long does it take for value stream mapping?
  • 6 weeks?
  • 4 weeks?
  • 1 week?
  • If it takes more than 4 hours, then we are
    wasting our time

10
Quote
Quote to Cash
Value stream map
  • Understanding the process
  • steps
  • Picking the process which has
  • more value impact
  • Picking right tools

Cash
This flow diagram required for ISO as well
10
11
Understanding Selected Tools and Techniques OEE
Overall Equipment Effectiveness Availability
x Performance x Quality x 100
12
Understanding Selected Tools and Techniques OEE
Understanding Selected Tools and Techniques OEE
Production Time Down Time Available Time
480 mins. 60 mins 480
A
X 100 87
X 100
of Boxes Produced Actual Machine Run Capability

8,000 10,000
P
X 100 80
X 100
Good Boxes Total of Boxes Run
98,000 100,000
Q
X 100 98
X 100
A availability P performance Q quality
OEE A x P x Q x 100 .87 x .80 x .98 x 100 68.2

13
Understanding Selected Tools and Techniques TAKT
Time

TAKT time is the rate at which customers require
the product TAKT time is computed as
Available work time per day(480-BREAKS) Daily
required customer demand in BOXES per day
14
Understanding Selected Tools and Techniques
Visual Management
  • Charts
  • Metrics
  • Procedures
  • Process documentation

15
Understanding Selected Tools and Techniques
Quick Setups
  • SMED
  • Effective implementation of 6S
  • Machine center lining, zero gear trains, time and
    register
  • Standardization of cutting dies and printing
    plates

16
Understanding Selected Tools and Techniques
Kanban
  • A pull material replenishment system, based on
    the principle that material is pulled through the
    production process based on actual usage of
    material
  • Kanban uses visual signals, usually a card, to
    move material through the value chain

17
Understanding Selected Tools and Techniques
Kaizen
  • Continuous improvement through incremental
    improvement
  • The whole secret to Kaizen is to create an
    atmosphere, a culture of continuous improvement,
    by focusing on problems not on people .
  • Kaizen compliments the other tools of Lean and it
    is part of a whole rather than a stand-alone
    process

18
Lean Tools and TechniquesStatistical Problem
Solving
  • The steps of Statistical Problem Solving
  • Defining the problem
  • Listing suspected variables
  • Prioritizing variables using subjective rating
  • Evaluating the critical few variables by
    conducting studies and trials
  • Optimizing variable settings

19
QSEs Approach to Cost Reduction
  • Quotation to cash
  • Follow the money
  • Application of disciplined problem solving
  • Top 5 impacting items

20
Example Problems Picked By Our Customers
Maximum Impacting Bottom Line
  • Excessive inventory (wip, ink, sheets, finished
    goods)
  • Purchasing (cost of raw materials, uncontrolled
  • purchasing methods)
  • Set up time reduction
  • Over runs
  • Supplier sheets (defects)
  • Estimation, quotes time
  • Incomplete information on RFQs
  • Incorrect customer specs
  • Maintenance parts inventory (old obsolete,
    doubled up parts)
  • Ineffective or non-existing procedures and
    instructions

21
QSEs Proven Lean Implementation Guidance
  • Recognize lean as a long term journey
  • Recognize obstacles to change
  • Adequate resource allocation
  • Focus on both manufacturing and non manufacturing
    areas

22
QSEs Proven Lean Implementation Guidance
  • Benchmark but do not copy
  • One system
  • Synchronize lean goals with business goals
  • Empowerment / team approach
  • Create an atmosphere, a culture of continual
    improvement

23
Defined Path for Effective Lean Implementation
  • 1.Lean Tools and concepts training
  • 2. Baseline assessment/establishment of goals and
    metrics
  • 3. Selection of appropriate lean tools and
    concepts

24
Defined Path for Effective Lean Implementation
  • 4. Train the implementation team for the
    application of the selected tools and concepts
  • 5. Assist in the application of the selected
    tools and concepts

25
Defined Path for Effective Lean Implementation
  • 6. Monitor and audit improvement against goals,
    re-evaluate the process if necessary
  • 7. Fine-tuning of the processes to achieve
    value-added results

26
Defined Path for Effective Lean Implementation
  • 8. Maximize/optimize implementation effectiveness
    for bottom line improvement
  • 9. Incorporate results into standardized
    procedures
  • 10. Management review of accomplished results

27
Effective Lean Implementation QSE
Difference
  • Not just promise GUARANTEED 15 waste reduction
    from baseline assessment
  • Not just train ASSIST in implementation
  • Not just manufacturing ALL non manufacturing
    areas of the business

28
Effective Lean Implementation QSE
Difference
  • Not just problem identification ASSIST in
    systematic problem solving
  • Not just team building TRAIN the team in
    problem solving techniques

29
Effective Lean Implementation QSE
Difference
  • Not just lean, COMBINE ISO, lean and problem
    solving to sustain bottom line results
  • Integrate all lean procedures and instructions
    into one manageable simplified ISO process
    approach
  • Audit lean results for sustainability integrated
    with ISO auditing techniques

30
Successful Lean Implementation
  • No lean strategy will work until process is
    error proofed with
  • Disciplined/defined path
  • Problem solving techniques
  • Simplistic ISO (if applicable)

31
Successful Lean Implementation Integrate with ISO
  • One level documentation
  • Realistic
  • Practical
  • Internal auditing for continual improvement
  • Control of nonconformities
  • Corrective and Preventive action plans

32
Successful Lean Implementation Problem Solving
  • Systematic/Statistical Problem Solving
  • Effective root cause analysis
  • Apply sustainable, permanent problem solving
    techniques
  • Problem solving is a problem

33
Effective Lean Implementation Summary
  • Lean Focus
  • Definition of Lean Enterprise
  • Lean Tool Selection
  • Understanding Selected Tools/Techniques
  • QSEs Approach to Cost Reduction

34
Effective Lean Implementation Summary
  • QSEs Proven Lean Implementation Guidance
  • Defined Path for Effective Lean Implementation
  • Effective Lean Implementation QSE Difference
  • Successful Lean Implementation Integrate with ISO

35
Effective Lean Enterprise Summary
  • Successful Lean Implementation Problem Solving
  • Successful Lean Enterprise has commitment and
    involvement at all levels of the organization
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