Management Team Training 4-2-07

Management Overview of Lean at Industrial Mold & Machine

Vision Without Action is Just a Dream Action Without Vision is Just Wasting Time

Why Lean? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

NOT a Set of Tools: Kanban Standardized Work SMED Kaizen Andon What TPS is:

What TPS is: Human Development Philosophy Managerial Technical … An Integrated System c 2000 Toyota

LEAN PHILOSOPHY ,[object Object],[object Object],[object Object]

WASTE ,[object Object],[object Object],[object Object],Type 1 waste: NVA, but need now Type 2 waste: NVA and can eliminate quickly

WASTE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Key Questions to Eliminate Waste ,[object Object],[object Object],[object Object],[object Object]

Visual Devices Make It Easier ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Potential risk or loss if ignored Likelihood of being ignored

Common Visual Devices TYPE HOME COMMUNITY WORKPLACE Indicator Signal Control Guarantee Street Signs Truck Back- up beep Lines in Parking Lot Unleaded / Diesel Gasoline Filler Tube Sizes Clean/Dirty sign on dishwasher Buzzer on Dryer Kitchen Utensil Holder Large/small Side Appliance Plugs

Personal Knowledge Centralized Knowledge Public Knowledge The Visual Factory , Greif

LIVING LEAN: THE 5 KEY ELEMENTS ,[object Object],[object Object]

LIVING LEAN: THE 5 KEY ELEMENTS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

LIVING LEAN: THE 5 KEY ELEMENTS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

The 14 Principles of the Toyota Way ,[object Object],[object Object],[object Object],[object Object]

The 14 Principles of the Toyota Way (cont’d) ,[object Object],[object Object],[object Object],[object Object],[object Object]

The 14 Principles of the Toyota Way (cont’d) ,[object Object],[object Object],[object Object]

The 14 Principles of the Toyota Way (cont’d) ,[object Object],[object Object],[object Object],[object Object]

How Do We Get There? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

The TPS Goal – “Notion of the Ideal” ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Willing to start small, learn through trial and error TPS is built on the scientific way of thinking Develop a way of thinking: “how do I respond to this problem?”

Summary of Policy Deployment ,[object Object],[object Object],[object Object]

Methodology ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Selected lean tools ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],All to attain Perfect Value with Zero Waste

5 S -- Foundation for a Visual Workplace ,[object Object],[object Object],[object Object],[object Object],[object Object]

SMED (Single Minute Exchange of Die) ,[object Object],[object Object],[object Object],Reduce Changeover / Setup time to enable smaller lot sizes, respond more quickly to customers, increase capacity

STANDARDIZED WORK ,[object Object],[object Object]

Creating Standardized Work How can I create work so that it can be repeated? Most efficient work flow - considering safety, quality, quantity and cost 2/3 6/7 8/9 1 4 5 10 ,[object Object],[object Object],[object Object],[object Object]

KANBAN Pull Mechanism ,[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],Mistake Proofing Make it easy to do it right

Cellular Manufacturing ,[object Object],[object Object],[object Object],[object Object],Supports Flow

Management Team Training 4-2-07

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Management Team Training 4-2-07