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Lean Manufacturing Concepts
Lean Manufacturing Keys to Success
Lean Manufacturing Tools
Lean Case Studies
Key
Concepts of Winning Strategies
1.
Management Support / Methods
- Recognizing
that without management's support, the process will fail
- Understanding
that this is not just "another program", but a permanent
change from business as usual
- Identifying
key results / goals
- Focusing
on data and performance issues rather than personalities
- Communicating
openly and honestly
- Delegating
to subordinates
- Communicating
expectations and following up on performance to those expectations
2.
Front Line Leadership
- Implementing
basic principles to build an empowered work force
- Gathering
good information to make good decisions
- Using
positive recognition to support organizational goals and values
- Recognizing
that goal is a part of the win / win agreement
3.
Performance Management
- Defining
what employees should do - job description
- Defining
and communicating expectations of performance for each key
responsibility in the job description
- Providing
frequent feedback on performance results compared to expectations
4.
Quality Improvement System Measures
- Identify
Critical Success Factors (CSF) at the top company level and relate
them to Key Performance Indicators (KPI) at all levels of the
organization. This
should be linked to Process Performance Management with tools such
as control-ES Software.
- Assign
responsibility for processes and KPI’s
- Picking
problem areas and begin measuring trends
- Establishing
goal and trend chart based on key measurable
- Making
sure progress will be measured and charted
- Using
the "Dash Board" approach to measurements
5.
Employee Involvement / Problem Solving
- Providing
training as required
- Understanding
the available quality tools used for measurement
- Attacking
the problem, not the person
- Identifying
the problem and team to solve that problem
- Using
a team approach
6.
Rewards
- Rewarding
Problem Solving teams as they achieve their goals
- Basing
the type of reward on suggestions from the team
7.
Communication
- Glass
wall management
(Open communication throughout the entire organization; pertinent
information shared with everyone, therefore all people in the
company can participate
- Opening
communications up and down the line
- Internal
and external dissemination of "Best Practices"
8.
Planning Room
- A
physical place to show ongoing company performance
- A
designated place for planning and improvement activities
9.
Visual Management
- Shows
real-time performance indicators
- Shows
real-time reduction of waste
- Shows
scheduling of manufacturing and resources
- Shows
trend charts with goals
- Shows
recent corrective actions
- Shows
meeting minutes / notes
- Shows
employee picture board, by classification
- Shows
training matrix
10.
5 S / Housekeeping
- Sort
(organize workspace)
- Simplify
(easy reach of often used materials and tools)
- Sweep
(clean workspace)
- Standardize
(improve the Sort, Simplify and Sweep process)
- Sustain
(maintain the Sort, Simplify, Sweep and Standardize into daily
habit)
11.
Total Productive Maintenance (TPM)
- Maintaining
and improving equipment reliability - operators and maintenance
personnel
- Maintaining
equipment for maximum life utilization
- Maximizing
equipment effectiveness through employee involvement
12.
Production Setup Reduction
- Essential:
Reacting to smaller lot sizes
- Reacting
to customer demand and changing market conditions
- Reducing
changeover time for all production machines
13.
Effective Meetings
- Starting
and ending on time
- Keeping
meetings short
- Distributing
agenda before meeting
- Prioritizing
agenda items
- Not
letting difficult tasks stop meeting progress
14.
Production Planning
- Understanding
your customers' needs and requirements for the near future
- Seeking
best utilization of equipment, materials and personnel
- Reacting
sensibly to those needs to systematically plan labor and materials
purchases
15.
Production Reporting
- Reporting
performance daily to the production, inventory, and sales plans
- Timely
reporting enables sensible, timely responses to changing market
conditions
16.
Time Management
- Controlling
procrastination
- Controlling
events and taking action - and feeling good about it
- Effective
planning to achieve goals on time, every time
17.
Project Management
- Understanding
how to set realistic goals and priorities
- Understanding
how to separate value-added and non-value-added tasks and acting
only on the value-added tasks
- Organizing
work for team building
- Designing
work breakdown structures
- Tying
to key measurable they are improving
18.
Presentations
- Effectively
communicating results to others
- Researching
audience needs perspectives
- Selecting,
developing, and using the right visual aids
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