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1、What is Lean,Lean is a that focuses on: Creating value for the Customer Eliminating Waste Continuous incremental improvement,Thinking Process,1,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,What is a Value Stream,All of the actions, value or non value added that are requi
2、red to bring a product from concept to launch or from raw material order to delivery. . .,From “Lean Lexicon,2,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Order Fulfillment Value Stream,Ideally, wed want the materials, information and cash to flow smoothly (without inte
3、rruption) and as quickly as possible through this stream,3,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Lean Elements,Value Stream = Value Providing Processes,Pull,Perfection,Flow,Value,4,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Value,Wha
4、t is the willing to Pay for?” 3 Types of Customers: The external end-user or paying customer The downstream customer of any internal upstream process. Your company as the customer of external suppliers,Customer,5,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Flow,Ideal fl
5、ow = 1 piece at a time Rate determined by customer demand - Takt time Work balanced for each person or machine Travel distance for materials & people minimized Standard Work utilized Flow what you can Pull what you cant Requires that all steps in the process be: Capable = Right every time Available
6、= Always able to run Adequate = Capacity to avoid bottlenecks,6,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Phases of Lean Journey,Phase 1-Identify/Map Value Streams Phase 2-Prioritize opportunities Phase 3-Utilize Lean tools to eliminate waste Phase 4-Control the flow
7、Phase 5-Lean metrics Phase 6-Re-evaluate Value Streams and begin again,7,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,It All starts with Waste Identification,Identify all forms of Waste throughout our entire Value Stream before: Reducing the waste or Eliminating the wast
8、e This will enable us to prioritize our efforts and focus on the high potential events first,8,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,8 Wastes,Overproduction Inventory Waiting Transporting Unnecessary processing Unnecessary motion Defects Under utilization of peopl
9、e,9,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Over-Production,Producing more than what the customer really wants,Ways to Overcome: Reduce setup times Synchronize time and amount of processes Create compact layouts and visibility,10,ENERGIZER SCHICK - HIGHLY CONFIDENTI
10、AL - RESTRICTED FOR INTERNAL USE ONLY,Inventory,Excess inventory requires handling, space, $, people, and paperwork,Ways to Overcome: Synchronize work flow to reduce accumulation Shorten setup time Reduce lead time Cellular layouts Zero Quality Defects Reducing all other wastes reduces the waste of
11、inventory,11,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Waiting,Waiting for upstream processes due to poor layout, unbalanced work load or equipment downtime,Ways to Overcome: Synchronize work flow Balance uneven loads by flexible workers and equipment Implement preven
12、tive maintenance to eliminate machine down-time,12,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Transportation,Transportation adds No value to the product. Rather than improve the transportation: Reduce it Eliminate it,Ways to Overcome: Establish layout and locations whi
13、ch reduces or eliminates transportation,13,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Unnecessary Processing,Same data entered into 3 different information systems. (SAP, Access, Excel,All unnecessary, or Non- Value Added, processing steps should be eliminated,Ways to
14、Overcome: Question if process is necessary at all Simplify Use Standard Work Reduce Handoffs/approvals,14,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Unnecessary Motion,Motion of people, machines, and products is waste,Ways to Overcome: Study motion and eliminate or red
15、uce motion through improved layouts. Cellular Manufacturing Rethink material storage Job/Task Combinations,15,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Defects (Correction,Making defective product is pure (muda) waste. Focus on preventing defects Not finding and repai
16、ring defects,Ways to Overcome: Mistake-proof to prevent defects Never Pass defects Standard Work,16,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Waste of Underutilizing People,The eighth waste is not fully utilizing the time and talents of people. Who are the “real” experts ? and what do they know,17,ENERGIZER SCHICK - HIGHLY CONFIDENTIAL - RESTRICTED FOR INTERNAL USE ONLY,Purpose of Value Stream Mapping,The purpose of the value stream map is to look at the big pictu
