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1、TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation. 2003 TBM Consulting Group, Inc. All Rights Reserved.skbLean Production Lean Production SystemSystem3 - 2 2003 TBM Consulting Group, Inc. All Rights Reserved.skbKaizen Breakthrough Methodology6 s s Pro
2、cess CapabilityFocus on lead-time reduction to:Increase Customer Loyalty and Market ShareSustain the Competitive AdvantagesAchieve Growth in Sales & EarningsImprove Stakeholder ValueLeanProductionSystemLeanSigmaSM Transformation3 - 3 2003 TBM Consulting Group, Inc. All Rights Reserved.skbLean Produc
3、tion SystemJustinTimeJidokaEfficient Use of :PeopleEquipmentMaterialsSpace Production SmoothingImprove Process CapabilityMinimize VariationManage Abnormality3 - 4 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJust-In-Time Is.Just-In-Time Is.A manufacturing system which produces:What the cus
4、tomer wantsIn the quantity the customer wantsWhen the customer wants itWhile using the minimum:Raw materialsEquipmentLaborSpace3 - 5 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJIT PrinciplesJIT PrinciplesPace to “takt” timeCreate flow productionIncorporate “pull” system3 - 6 2003 TBM Con
5、sulting Group, Inc. All Rights Reserved.skbTakt TimeTakt Time3 - 7 2003 TBM Consulting Group, Inc. All Rights Reserved.skb1-Piece FlowBatchFake Flow3 - 8 2003 TBM Consulting Group, Inc. All Rights Reserved.skb“A Sea of WIP”“Now You See It!”3 - 9 2003 TBM Consulting Group, Inc. All Rights Reserved.sk
6、bPull SystemPull System3 - 10 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJIT ElementsJIT ElementsSmall, inexpensive machines in process orderOne-piece flow production, counterclockwiseErgonomically-correct operationsStanding operations, moving while workingPull system discipline“Standard
7、 operations” defined and implemented3 - 11 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJIT BenefitsJIT BenefitsEliminates waste in production processesReduces lead timesQuality Cost Delivery!Creates a system which is intolerant of production abnormalities3 - 12 2003 TBM Consulting Group,
8、Inc. All Rights Reserved.skbLean Production SystemJustinTimeJidokaEfficient Use of :PeopleEquipmentMaterialsSpace Production SmoothingImprove Process CapabilityMinimize VariationManage Abnormality3 - 13 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJidoka isJidoka isAn immediate response to
9、 an abnormal condition within the processGoal: Prevent a defective product from being passed to the next operation.Equipment autonomation capable machine processes that enable separation of machine and operatorGoal: Multi-process handling, increased labor productivity.3 - 14 2003 TBM Consulting Grou
10、p, Inc. All Rights Reserved.skbAbnormality Response ProcessAbnormality Response ProcessReact to problemQ C D S Measure impactAlert teamTrain affected associates in new standard operationsMANEFFECTMACHINEMATERIALMETHODFind root causeDevelop and test improvementCheck 2BGauge 4Update standard operation
11、s with tested improvement3 - 15 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJidoka ElementsJidoka ElementsVisual Control5SAndonAbnormality Response/ReactionRoles and responsibilitiesLine stop guidelinesRoot Cause Analysis (DMAIC)Basic QC ToolsAdvanced Statistical ToolsMistake-proofing (Po
12、ke-Yoke)Manual WorkAutomatic machine workNew Standard Operations and trainingSkill matrix and performanceAutonomation Separate person from machine3 - 16 2003 TBM Consulting Group, Inc. All Rights Reserved.skbHave Machines Detect AbnormalitiesHave Machines Detect AbnormalitiesMetal Punch Press Exampl
13、e00343 - 17 2003 TBM Consulting Group, Inc. All Rights Reserved.skbJidoka BenefitsJidoka BenefitsIncreases production qualityIncreases productivityEnsures on-time deliveryQuality . Cost . Delivery!3 - 18 2003 TBM Consulting Group, Inc. All Rights Reserved.skbLean Production SystemJustinTimeJidokaEff
14、icient Use of :PeopleEquipmentMaterialsSpace Production SmoothingImprove Process CapabilityMinimize VariationManage Abnormality3 - 19 2003 TBM Consulting Group, Inc. All Rights Reserved.skbProduction Smoothing Is.Production Smoothing Is.Adapting production rates to variations in customer demand:Vari
15、ation in volumeVariation in product mix3 - 20 2003 TBM Consulting Group, Inc. All Rights Reserved.skbCustomer DemandVariation in VolumeVariation in VolumeAvg. Daily Demand = Target ProductionQuantityTime3 - 21 2003 TBM Consulting Group, Inc. All Rights Reserved.skbVariation in MixDayMonthly Schedule
16、(3200 units)5152010Model “A”1600 unitsModel “C”800 unitsModel “B”800 unitsDayDaily Schedule (160 units) Production pattern: AABCAABCA801B40C40A802B40C40A803B40C40A8020B40C403 - 22 2003 TBM Consulting Group, Inc. All Rights Reserved.skbProduction Smoothing BenefitsProduction Smoothing BenefitsMaintai
17、ns a consistent, high product qualityReduces the requirements for capital investmentReduces staffing costsEnsures on-time deliveryQuality . Cost . Delivery!3 - 23 2003 TBM Consulting Group, Inc. All Rights Reserved.skbLean Production SystemJustinTimeJidokaEfficient Use of :PeopleEquipmentMaterialsSpace Production SmoothingImprove Process CapabilityMinimize VariationManage Abnormality“Results in Cost Reduction”
